Building panels with drainage, drying, and ventilation properties and methods of manufacturing

Abstract

Methods of manufacture, building panels, and / or the like are provided. According to various embodiments, there is provided a method of manufacturing a building panel, the method including placing a building panel mat adjacent to a hot press comprising a caul plate, wherein the caul plate comprises one or more embossing features; pressing the caul plate into the mat; and maintaining contact between the caul plate against the building panel mat such that one or more embossed features are created on the building panel mat and the mat is finished into a building panel. In some embodiments, the building panel includes one or more embossed features disposed on its surface, wherein the one or more embossed features are configured to provide moisture resistance, drainage, drying, and / or ventilation to the building panel.

Description

BUILDING PANELS WITH DRAINAGE, DRYING, AND VENTILATION PROPERTIES AND METHODS OF MANUFACTURINGTECHNICAL FIELD

[0001] The present disclosure relates generally to building panels. In particular, it relates to embossing the surface of building panels to improve drainage and water resistance.BACKGROUND

[0002] Building panels, such as oriented strand board, require drainage properties, water resistance, and / or ventilation to prevent moisture build-up or other elemental deterioration.

[0003] Through applied effort, ingenuity, and innovation, the Applicant has solved problems relating to building panels by developing solutions embodied in the present disclosure, which are described in detail below.SUMMARY

[0004] In general, embodiments of the present disclosure provide building panels, methods of manufacturing, and / or the like.

[0005] In accordance with various embodiments of the present disclosure there is provided a building panel having one or more embossed features disposed on a surface of the building panel, wherein the one or more embossed features are configured to provide moisture resistance, drainage, drying, and / or ventilation to the building panel.

[0006] In some embodiments, the one or more embossed features include one or more extrusions.

[0007] In some embodiments, the building panel is oriented strand board (OSB).

[0008] In some embodiments, the one or more embossed features are generated by hot pressing one or more caul plates on the surface of the building panel. As used herein the term “unfinished building panel mat” means a section of building panel precursor material suitable for finishing in a hot press to make a finished building panel.

[0009] In some embodiments, the one or more caul plates include one or more embossing features.

[0010] In some embodiments, the one or more embossing features are holes disposed through the caul plate.

[0011] In some embodiments, the one or more embossing features of the caul plate include bevels.

[0012] In some embodiments, the one or more embossed features are disposed in a grid pattern on the surface of the building panel.

[0013] In some embodiments, the one or more embossed features are circles have a diameter ranging between 8 and 12 millimeters.

[0014] According to various embodiments, there is provided a method of manufacturing a building panel, the method including placing a building panel mat adjacent to a hot press having a caul plate, wherein the caul plate has one or more embossing features; pressing the caul plate into the building panel mat; and maintaining contact between the caul plate against the building panel mat such that one or more embossed features are created on the building panel mat and the mat is finished into a building panel.

[0015] In some embodiments, the finished building panel has an embossed surface.

[0016] In some embodiments, the caul plate is held against the building panel mat for a period of time ranging from 2 minutes to 5 minutes.

[0017] In some embodiments, the face temperature of the hot press is from about > 400 degreesFahrenheit to about < 500 degrees Fahrenheit.

[0018] In some embodiments, the face temperature of the hot press is controlled around a set point of about 450 degrees Fahrenheit.

[0019] In some embodiments, the one or more embossing features of the caul plate have holes disposed through the caul plate.

[0020] In some embodiments, the one or more embossing features of the caul plate have bevels.

[0021] The above summary is provided merely for purposes of summarizing some example embodiments to provide a basic understanding of some embodiments of the disclosure. Accordingly, it will be appreciated that the above-described embodiments are merely examples. It will be appreciated that the scope of the disclosure encompasses many potential embodiments in addition to those here summarized, some of which will be further described below.BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

[0022] Having thus described the disclosure in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

[0023] FIG. 1 shows a top view of an example building panel and example caul plates in accordance with various embodiments of the present disclosure;

[0024] FIG. 2A shows a top view of an example building panel in accordance with various embodiments of the present disclosure;

[0025] FIG. 2B shows a detail view of an example building panel in accordance with various embodiments of the present disclosure;

[0026] FIG. 3 A shows an isometric view of an example caul plate in accordance with various embodiments of the present disclosure;

[0027] FIG. 3B shows a detail view of an example caul plate in accordance with various embodiments of the present disclosure;

[0028] FIG. 4A shows an isometric view of an example caul plate in accordance with various embodiments of the present disclosure;

[0029] FIG. 4B shows a detail view of an example caul plate in accordance with various embodiments of the present disclosure; and

[0030] FIG. 5 is a flow chart illustrating an example method of embossing the surface of an example building panel in accordance with various embodiments of the present disclosure.DETAILED DESCRIPTION OF SOME EXAMPLE EMBODIMENTS

[0031] Various embodiments of the present disclosure now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the disclosure are shown. Indeed, this disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. The term “or” (also designated as “ / ”) is used herein in both the alternative and conjunctive sense, unless otherwise indicated. The terms “illustrative” and “exemplary” are used to be examples with no indication of quality level. Like numbers may refer to like elements throughout. Any measurements and units shown in the various drawings are exemplary only. The phrases “in one embodiment,” “according to one embodiment,” “according to various embodiments,” “in some embodiments,” and / or thelike generally mean that the particular feature, structure, or characteristic following the phrase may be included in at least one embodiment of the present disclosure and may be included in more than one embodiment of the present disclosure (importantly, such phrases do not necessarily refer to the same embodiment).Overview

[0032] According to various embodiments, building panels, such as oriented strand board (OSB), may be manufactured by cutting logs, recovering the cut logs, debarking the logs, stranding the logs by precision cutting, sifting and separating the strands with wet bins, and conveying the strands to dryers. After the strands are dried, they may be blended with resins or wax and then formed with forming heads into unfinished building panel mats. The unfinished building panel mats may then be pressed using one or more caul plates to finish them into building panels. The OSB may be pressed by the caul plate at temperatures suitable to cure the binder for sufficient time to effect curing. Examples of suitable temperatures can include from > 400 degrees Fahrenheit to < 500 degrees Fahrenheit. Examples of suitable curing times depend on the selection of binder and can range from about one minute to about three and a half minutes as wood fibers are forced up into the holes or beveled surface of the cauls on a hot press, for about 3 and a half minutes as wood fibers get forced up into the holes or beveled surface of the cauls on the hot press. In some embodiments, the unfinished building panel mat may include waxes and resins (along with the strands and other tree recovery by products) and the unfinished building panel mat can range in thickness from (> 2 to < 5 inches thick). During manufacturing the OSB may travel along a conveyor belt where it is formed under heat and pressure. In some embodiments, the amount of moisture in the substrate to affect the extrusion during the manufacturing process. Moisture control is an important independent variable as the moisture at least partially evaporates while the unfinished building panel mat is being finished in the hot press. It will be understood that too much vapor in the unfinished building panel mat may damage or destroy the OSB panels. In some embodiments, moisture content of the fibers near the surface of the board might be different than moisture content of the fibers in the core. Although reference has been made to the OSB, the building panel may be made of other pressed materials including (but not limited to) plywood, particle board, and / or fiber board.Example Building Panels

[0033] FIG. 1 shows a top view of an example building panel 100 and a first example caul plate 200 and a second example caul plate 300 in accordance with various embodiments of the present disclosure. In the depicted embodiment, the first example caul plate 200 or the second example caul plate 300 may be hot pressed onto the building panel 100 during manufacturing, as described. According to various embodiments, the first example caul plate 200 and the second example caul plate 300 may have different embossing elements to vary the embossed features on the building panel 100. In some embodiments, the embossing elements may add various water resistance features, drainage properties, and other beneficial elements (e.g., drying, ventilation) to the building panel 100.

[0034] FIG. 2A shows a top view of an example building panel 100 in accordance with various embodiments of the present disclosure. In some embodiments, the building panel 100 may comprise a building panel surface 102 that may be composed of OSB. In the depicted embodiment, the building panel 100 includes one or more embossed features 104. The one or more embossed features 104 may be protrusions or extrusions on the surface of the building panel 100. The one or more embossed features 104 may be spaced to optimize drainage or other desirable features. In some embodiments, the building panel 100 may include a water-resisting film or coating. In some embodiments, the building panel 100 may be formulated with a HydroGap® Drainable Housewrap product available from the Benjamin Obdyke Company.

[0035] FIG. 2B shows a detail view of the example building panel 100 in accordance with various embodiments of the present disclosure. As shown, the embossed feature 104 may be a raised portion of the building panel 100. As shown, the embossed feature 104 has a scored line 106 that forms a ring around the embossed feature 104. In some embodiments, the embossed feature 104 may be approximately 10 mm in diameter and configured to drain moisture from the building panel 100. Although the embossed feature 104 is shown as a raised feature in the various figures, it will be understood that the embossed feature may be an impression or a depression in the building panel 100.

[0036] FIG. 3A shows an isometric view of an example caul plate 200 in accordance with various embodiments of the present disclosure. As shown, the caul plate 200 is a square or rectangular plate having one or more embossing features 202 disposed in a grid on a surface of the caul plate 200. In some embodiments, the caul plate 200 may be a metal plate composed ofaluminum, stainless steel, or mild steel. In some embodiments, the caul plate 200 may be hot pressed onto the building panel 100 during manufacturing to create the one or more embossed features 104. In some embodiments, the shape of a main press for the hot press process may be made in the shape of the caul plate 200, eliminating the need to use the caul plate 200 in the hot press process. In some embodiments, the hot pressing process may a continuous press operation

[0037] FIG. 3B shows a detail view of an example caul plate 200 in accordance with various embodiments of the present disclosure. In the depicted embodiment, the caul plate 200 includes one or more embossing elements 202. As shown, the embossing element 202 may be a beveled feature that is not disposed entirely through the caul plate 200. In some embodiments, during the manufacturing of the building panel 100, the caul plate 200 may be hot pressed onto the panel 100 and the embossing elements 202 may cause an extrusion or other embossing of the panel 100 and thereby create the embossed features 104.

[0038] FIG. 4A shows an isometric view of an example caul plate 300 in accordance with various embodiments of the present disclosure. In the depicted embodiment, the caul plate 300 includes one or more embossing elements 302. The description of the caul plate 200 and its embossing element 202 may apply similarly to the caul plate 300 and its one or more embossing elements 302, respectively. It will be understood that, according to various embodiments, the placement of the embossing elements 302 on the caul plate 300 in a grid pattern may be similar or different from the placement of the embossing elements 202 on the caul plate 200 in its respective grid pattern.

[0039] FIG. 4B shows a detail view of an example caul plate 300 in accordance with various embodiments of the present disclosure. In the depicted embodiment, the embossing elements 302 are different than the embossing element 202 in that the embossing element 302 are disposed through the caul plate 302. In some embodiments, having the embossing element 302 be disposed through the caul plate 302 may improve moisture ventilation of the building panel 100 during the hot pressing during manufacturing. Although the embossing elements 202 and 302 are shown as circular holes, it will be understood that the embossing elements 202, 302 may be any suitable shape, including (but not limited to) half-moons and diamonds. In some embodiments, the embossing elements 202, 302 may cause the embossed features 104 of the building panel 102 to have a convex shape such that an upper portion of the embossed features 104 faces upwardly when installed to promote good water drainage. It will be understood that the shape may be any shapeallowing for water to flow over or around the embossing elements 202, 302 and that does not allow for water to pool or collect on the embossing elements 202, 302.Example Methods of Manufacturing Building Panels

[0040] FIG. 5 is a flow chart illustrating an example method 400 of manufacturing an example building panel in accordance with various embodiments of the present disclosure. The method 400 is described with respect to the building panel 100 and caul plates 200, 300 as previously shown and described. It will be understood that the method 400 may be used with other suitable building panels and caul plates, as desired.

[0041] In some embodiments, the method 400 includes a step 402 of placing a building panel mat adjacent to a hot press having a caul plate. In some embodiments, the method 400 includes a step 404 of pressing the caul plate into the building panel mat. In some embodiments, the method 400 includes a step 406 of maintaining contact between the caul plate against the building panel mat such that one or more embossed features are created on the building panel mat and the mat is finished into a building panel.

[0042] Many modifications and other embodiments of the disclosure set forth herein will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the disclosure is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

CLAIMS1. A building panel comprising one or more embossed features disposed on a surface of the building panel, wherein the one or more embossed features are configured to provide moisture resistance, drainage, drying, and / or ventilation to the building panel.

2. The building panel of claim 1, wherein the one or more embossed features comprise one or more extrusions.

3. The building panel of claim 2, wherein an upper surface of an embossed feature of the one or more embossed features is convex.

4. The building panel of claim 1, wherein the building panel comprises oriented strand board (OSB).

5. The building panel of claim 1, wherein the one or more embossed features are generated by hot pressing of one or more caul plates on a surface of a building panel mat before finishing the building panel mat into the building panel with hot pressing.

6. The building panel of claim 5, wherein the one or more caul plates comprise one or more embossing features.

7. The building panel of claim 6, wherein the one or more embossing features comprise holes disposed through the caul plate.

8. The building panel of claim 6, wherein the one or more embossing features of the caul plate comprise bevels.

9. The building panel of claim 1, wherein the one or more embossed features are disposed in a grid pattern on the surface of the building panel.

10. The building panel of claim 1, wherein the one or more embossed features circles having a diameter ranging between 8 and 12 millimeters.

11. A method of manufacturing a building panel, the method comprising: placing a building panel mat adjacent to a hot press comprising a caul plate, wherein the caul plate comprises one or more embossing features; pressing the caul plate into the building panel mat; and maintaining contact between the caul plate against the building panel mat such that one or more embossed features are created on the building panel mat and the mat is finished into a building panel.

12. The method of claim 11, further comprising recovering a finished building panel having an embossed surface.

13. The method of claim 11, wherein the caul plate is held against the building panel mat for a period of time ranging from 2 minutes to 5 minutes.

14. The method of claim 13, wherein the face temperature of the hot press is from about 400 degrees Fahrenheit to about 500 degrees Fahrenheit.

15. The method of claim 13, wherein the face temperature of the hot press is controlled around a set point of 450 degrees Fahrenheit.

16. The method of claim 11, wherein the one or more embossing features of the caul plate comprise holes disposed through the caul plate.

17. The method of claim 11, wherein the one or more embossing features of the caul plate comprise bevels.

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