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US 12,583,146 B2Granted
Composite products
OwnerRichard Hand, Liam Johnsoninventors
Life of this patent
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Abstract
A sugar-based binder composition for manufacturing a composite product, notably a wood board, comprises at least one further particulate additive selected from the group consisting of: particulate additive(s) having a BET specific surface area which is ≥50 m2/g; amorphous silica particles; fumed silica particles; and untreated fumed silica particles.
Claims28
A method of manufacturing a wood board, comprising:
- applying a binder composition in the form of an aqueous solution to loose wood matter to provide resinated loose wood matter,
- arranging the resinated wood matter as a sheet of loosely arranged resinated wood matter;
- and
- subjecting the sheet of loosely arranged resinated wood matter to heat and pressure to cure the binder composition and to form the wood board from the sheet of loosely arranged resinated wood;
- wherein the binder composition is a sugar-based binder composition which comprises:
- polymerizable reactants, wherein at least 50% by dry weight of the polymerizable reactants comprise reactants selected from:
- i) one or more reducing sugar reactants;
- ii) one or more reactants which under curing conditions will generate one or more reducing sugar reactants;
- iii) curable reaction product(s) of one or more reducing sugar reactant(s);
- iv) reactants which under curing conditions will react with the one or more reducing sugar reactants;
- and v) combinations of the aforementioned reactants;
- and
- at least one particulate additive selected from the group consisting of:
- particulate additive(s) having a BET specific surface area which is ≥50 m2/g as measured in accordance with the ISO 9277 standard;
- amorphous silica particles;
- and
- fumed silica particles;
- wherein the at least one particulate additive makes up at least 5% by dry weight of the sugar-based binder composition.
15 more elements
A method of manufacturing plywood comprising a stack of individual veneers, the method comprising:
- applying a binder composition in the form of an aqueous solution, to one or more of the individual veneers to provide one or more individual resinated veneers,
- arranging the one or more individual resinated veneers in the stack of individual veneers wherein the direction of the grain in adjacent veneers is offset at right angles;
- and
- subjecting the stack to heat and pressure to cure the binder composition to form the plywood;
- wherein the binder composition is a sugar-based binder composition which comprises:
- polymerizable reactants, wherein at least 50% by dry weight of the polymerizable reactants comprise reactants selected from:
- i) one or more reducing sugar reactants;
- ii) one or more reactants which under curing conditions will generate one or more reducing sugar reactants;
- iii) curable reaction product(s) of one or more reducing sugar reactant(s);
- iv) reactants which under curing conditions will react with the one or more reducing sugar reactants;
- and v) combinations of the aforementioned reactants;
- and
- at least one particulate additive selected from the group consisting of:
- particulate additive(s) having a BET specific surface area which is ≥50 m2/g as measured in accordance with the ISO 9277 standard;
- amorphous silica particles;
- and
- fumed silica particles;
- wherein the at least one particulate additive comprises fumed silica particles and makes up at least 5% by dry weight of the sugar-based binder composition.
15 more elements
A method of manufacturing a wood board, comprising:
- applying a binder composition in the form of an aqueous solution to loose wood matter to provide resinated loose wood matter,
- arranging the resinated wood matter as a sheet of loosely arranged resinated wood matter;
- and
- subjecting the sheet of loosely arranged resinated wood matter to heat and pressure to cure the binder composition and to form the wood board from the sheet of loosely arranged resinated wood;
- wherein the binder composition is a sugar-based binder composition which comprises:
- polymerizable reactants, wherein at least 50% by dry weight of the polymerizable reactants comprise reactants selected from:
- i) one or more reducing sugar reactants;
- ii) one or more reactants which under curing conditions will generate one or more reducing sugar reactants;
- iii) curable reaction product(s) of one or more reducing sugar reactant(s);
- iv) reactants which under curing conditions will react with the one or more reducing sugar reactants;
- and v) combinations of the aforementioned reactants;
- and
- fumed silica particles, wherein the fumed silica particles make up at least 5% by dry weight of the sugar-based binder composition.
10 more elements
Dependencies are inferred from the claim text.