# US 12,005,603 B2 · Production of wood particle panels resistant to liquid water penetration

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- Number: US 12,005,603 B2
- Document ID: US12005603B2
- Status: Granted
- Kind: B2
- Application number: 17/558,005
- Filed: 2021-12-21
- Published: 2022-06-23
- Granted: 2024-06-11
- Earliest claimed: 2020-12-21
- Assignees: Norbord Inc.
- Applicants: Norbord Inc.
- Inventors: Aleksander Nadezhdin; Claude Ostiguy; Elizabeth Cacchione; Karina Martinez Villegas; Alain Laplante
- Web page: https://patentgrep.com/patent/US12005603B2

## CPC

- B27N 1/006: {for increasing resistance to swelling by humidity}
- B27N 7/005: {Coating boards, e.g. with a finishing or decorating layer}
- B27N 7/00: After-treatment, e.g. reducing swelling or shrinkage, surfacing; Protecting the edges of boards against access of humidity
- B32B 3/12: characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
- B32B 5/022: {Non-woven fabric}
- B32B 5/266: {next to one or more non-woven fabric layers}
- B32B 21/02: {the layer being formed} of fibres, chips, or particles {, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard}
- B27N 3/002: {characterised by the type of binder (compositions of macromolecular compounds C08L)}
- B27N 3/02: from particles
- B27N 3/04: from fibres
- B32B 2250/20: All layers being fibrous or filamentary
- B32B 2255/02: on fibrous or filamentary layer
- B32B 2255/08: on wood layer
- B32B 2255/26: Polymeric coating
- B32B 2255/28: Multiple coating on one surface
- B32B 2260/021: Fibrous or filamentary layer
- B32B 2260/046: Synthetic resin
- B32B 2262/067: Wood fibres
- B32B 2307/514: Oriented
- B32B 2307/7242: Non-permeable
- B32B 2307/7265: Non-permeable
- B32B 2307/73: Hydrophobic
- B32B 2607/00: Walls, panels
- B27N: MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL (containing cementitious material B28B; shaping of substances in a plastic state B29C; fibreboards made from fibrous suspensions D21J; drying F26B17/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM

## Abstract

A method of can be used to make a wood composite material. The method includes forming a panel having wood fibers and additives, sanding a main surface of the panel, applying a polymer to the sanded main surface of the panel, and curing the polymer by irradiating the main surface of the panel. After the curing, the main surface has a solid discontinuous composite including a mixture of the wood fibers and cured polymer micro-islands.

## Claims

### Claim 1

A method of making a wood composite material, the method comprising:
forming a panel comprising wood fibers and additives;
sanding a main surface of the panel;
applying a polymer to the sanded main surface of the panel; and
curing the polymer by irradiating the main surface of the panel, wherein, after curing, the main surface comprises a solid discontinuous composite including a mixture of the wood fibers and cured polymer micro-islands.

### Claim 2 (depends on 1)

The method of claim 1, wherein forming the panel comprises forming an oriented strand board (OSB) panel having a core layer sandwiched between a first outer layer and a second outer layer, the main surface being an external surface of the second outer layer.

### Claim 3 (depends on 1)

The method of claim 1, wherein sanding the main surface comprises sanding with a grit finish between 60 and 120.

### Claim 4 (depends on 1)

The method of claim 1, wherein applying the polymer comprises performing a spraying process, a curtain coating process, a flooding process, or a roller coating process.

### Claim 5 (depends on 1)

The method of claim 1, wherein applying the polymer comprises applying a 100% active UV coating that includes an initiator, a polymer, and a monomer.

### Claim 6 (depends on 1)

The method of claim 1, wherein applying the polymer comprises applying between 40 g/m2 and 120 g/m2 of polymer onto the main surface.

### Claim 7 (depends on 6)

The method of claim 6, wherein, after the irradiating, the main surface is characterized by a vapor permeability in a range from about 0.1 U.S. perms to about 12 U.S. perms as determined by ASTM E96 method B and a liquid water transmission rate from about 1 to about 28 grams/100 in2/24 hours according to the test method described in ASTM D5795.

### Claim 8 (depends on 1)

The method of claim 1, wherein, after the irradiating, the main surface is characterized by a vapor permeability in a range from about 0.1 U.S. perms to about 12 U.S. perms as determined by ASTM E96 method B.

### Claim 9 (depends on 1)

The method of claim 1, wherein, after the irradiating, the main surface is characterized by a liquid water transmission rate from about 1 to about 28 grams/100 in2/24 hours according to the test method described in ASTM D5795.

### Claim 10 (depends on 1)

The method of claim 1, wherein applying the polymer comprises applying two coats of the polymer.

### Claim 11 (depends on 10)

The method of claim 10, wherein applying and curing the polymer comprises in the stated order:
performing a first spraying step;
removing excess polymer from the first spraying step using a pick up roller;
performing a first cure;
performing a second spraying step;
removing excess polymer from the second spraying step using a pick up roller; and
performing a second cure.

### Claim 12 (depends on 10)

The method of claim 10, wherein applying and curing the polymer comprises in the stated order:
performing a first spraying step;
removing excess polymer from the first spraying step using a pick up roller;
performing a first cure;
roll coating a second polymer layer; and
curing the second polymer layer.

### Claim 13 (depends on 1)

The method of claim 1, wherein applying the polymer comprises applying three coats of the polymer, applying and curing the polymer comprising in the stated order:
performing a first spraying step;
removing excess polymer from the first spraying step using a pick up roller;
performing a first cure;
performing a second spraying step;
removing excess polymer from the second spraying step using a pick up roller; and
performing a second cure;
roll coating a third polymer layer; and
curing the third polymer layer.

### Claim 14 (depends on 1)

The method of claim 1, further comprising applying a dye to the main surface at the same time as applying the polymer.

### Claim 15

A method of making a wood composite material, the method comprising:
forming an OSB panel comprising wood fibers and additives;
sanding a main surface of the panel with a grit finish between 60 and 120;
applying between 40 g/m2 and 120 g/m2 of a water-based UV polymer to the sanded main surface of the panel using a spray technology;
heating the panel at a temperature between 50° C. and 80° C. to remove water from the polymer; and
curing the polymer by irradiating the main surface of the panel with UV radiation, wherein, after curing, the main surface comprises a solid discontinuous composite including a mixture of the wood fibers and cured polymer micro-islands.

### Claim 16 (depends on 15)

The method of claim 15, wherein applying the polymer comprises spraying between 40 g/m2 and 100 g/m2 of the polymer using a spray gun directed at a −90° angle relative to a plane of the main surface of the panel.

### Claim 17 (depends on 15)

The method claim 15, further comprising applying a second coat of the water-based UV polymer prior to curing the polymer.

### Claim 18

A method of making a wood composite material, the method comprising:
forming an OSB panel comprising wood fibers and additives;
sanding a main surface of the panel;
applying between 79 g/m2 and 120 g/m2 of a UV polymer to the sanded main surface of the panel using a spray technology;
removing excess polymer from the main surface; and
curing the polymer by irradiating the main surface of the panel with UV radiation, wherein, after curing, the main surface comprises a solid discontinuous composite including a mixture of the wood fibers and cured polymer micro-islands.

### Claim 19 (depends on 18)

The method of claim 18, wherein applying the UV polymer comprises applying the two coats of the UV polymer.

### Claim 20 (depends on 18)

The method of claim 18, wherein curing the polymer comprises first using a first UV lamp at a first power level to get a gel cure and then using a second UV lamp at a second power level to get a full cure, the second power level greater than the first power level.