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US 11,453,780 B2Granted
Composite wood board
AssigneesKnauf Insulation, Inc., Knauf Insulation SPRL
InventorsRoger Jackson, Tony Aindow, George Baybutt
Life of this patent
Estimating the term…
Abstract
In a stack of composite wood boards, the wood boards comprise wood particles and an organic binder.
Claims20
A method of manufacturing a composite wood board comprising:
- applying an uncured, aqueous, thermosetting binder solution to non-or loosely assembled wood matter to provide resinated wood matter;
- and
- hot pressing the resinated wood matter to cure the uncured, aqueous, thermosetting, binder and form the composite wood board;
- wherein the uncured, aqueous, thermosetting binder solution is prepared by combining reactants including i) a reducing sugar reactant provided in the form of a reducing sugar per se or in the form of a carbohydrate which yields a reducing sugar in situ under thermal curing conditions, or a combination thereof;
- and ii) an amine reactant, wherein the amine reactant comprises a non-protein primary amine reactant +NH3R1, where R1 is alkyl substituted by a group selected from at least one amino and at least one aminoalkyl and wherein R1 does not comprise a secondary amino group;
- and
- wherein the composite wood board has one or more of the following characteristics:
- a modulus of elasticity (MOE) of at least 1800 N/mm2;
- a bending strength (MOR) of at least 14 N/mm2;
- an Internal bond strength (IB) of at least 0.28 N/mm2;
- a thickness swelling after 24 hours in water at 20° C. of less than or equal to 12%;
- a water absorption after 24 hours in water at 20° C. of less than or equal to 40%.
9 more elements
A method of manufacturing a composite wood board comprising:
- applying an uncured, aqueous, thermosetting binder solution to non-or loosely assembled wood matter to provide resinated wood matter;
- and
- hot pressing the resinated wood matter to cure the uncured, aqueous, thermosetting binder and form the composite wood board;
- wherein the uncured, aqueous, thermosetting, organic binder solution is prepared by combining reactants including i) a reducing sugar reactant provided in the form of a reducing sugar per se or in the form of a carbohydrate which yields a reducing sugar in situ under thermal curing conditions, or a combination thereof;
- and ii) an amine reactant, wherein the amine reactant comprises a non-protein primary amine reactant +NH3R1, where R1 is alkyl substituted by a group selected from at least one amino and at least one aminoalkyl and wherein R1 does not comprise a secondary amino group;
- and
- wherein preparation of the uncured, aqueous, thermosetting binder solution comprises combining the reducing sugar reactant(s) and the amine reactant such that the amount of reducing sugar reactant(s) is from about 73% to about 96% of the total weight of reactants;
- wherein the composite wood board has a binder content in the range of 8 to 18% by weight expressed as weight of dry binder to weight of dry wood;
- and
- wherein the composite wood board has:
- a modulus of elasticity (MOE) of at least 1800 N/mm2;
- and
- a bending strength (MOR) of at least 14 N/mm2;
- and
- an Internal bond strength (IB) of at least 0.28 N/mm2;
- and
- a thickness swelling after 24 hours in water at 20° C. of less than or equal to 12%;
- and
- a water absorption after 24 hours in water at 20° C. of less than or equal to 40%.
16 more elements
Dependencies are inferred from the claim text.