Apparatus and method of manufacturing synthetic boards

In the production of synthetic boards from cellulosic fibers, an apparatus adapted for mixing a binder stream and a diluent stream and applying a product stream to the fibers, the apparatus comprising:

• binder inlet means for receiving a first stream containing a binder;
• diluent inlet means for receiving a second stream containing a diluent;
• mixing means fluidly connected to the binder inlet means and the diluent inlet means for mixing the first stream and the second stream to produce a third stream containing a product comprising the binder and the diluent;
• outlet means positioned proximate the mixing means and fluidly connected to the mixing means for immediately applying the third stream to the fibers;
• and
• flush means for flushing the mixing means with the second stream after flow of the first stream is stopped.

An apparatus for producing synthetic boards from a cellulosic material, and a highly reactive multi-part binder system including a binder and a diluent comprising:

• refining means for extracting fibers from a cellulosic material;
• conduit means connected to the refining means for conveying the fibers along a fiber flow path;
• binder application means for mixing a binder and a diluent to form a binder/diluent mixture and immediately mixing the binder/diluent mixture with the fibers in the fiber flow path;
• said binder application means including a static in-line mixing section having a continuously open outlet end connected to said conduit means and opening into the interior of the conduit means and a continuously open inlet end, binder inlet means connected to said inlet end, and diluent inlet means connected to said inlet end, such that a binder stream and a diluent stream merge at the inlet end, mix in the mixing section and merge with the fiber stream at the outlet end;
• dryer means for partially dewatering the fiber/binder mixture;
• forming means for creating a mat of the dewatered fiber/binder mixture;
• and
• heated pressing means for compressing the fibers and curing the binder in the mat for forming a consolidated board product.

An apparatus for producing synthetic boards from a cellulosic material, comprising:

• refining means for extracting fibers from a cellulosic material;
• conduit means connected to the refining means for conveying the fibers along a fiber flow path;
• binder application means for mixing a binder and a diluent to form a binder/diluent mixture and immediately mixing the binder/diluent mixture with the fibers in the fiber flow path;
• dryer means for partially dewatering the fiber/binder mixture;
• forming means for creating a mat of the dewatered fiber/binder mixture;
• heated pressing means for compressing the fibers and curing the binder and the mat for forming a consolidated board product;
• and
• flush means for flushing the binder/diluent mixture from the binder application means at the end of a production run wherein the flush means comprises means for stopping the flow of binder from the first stream and then stopping the flow of diluent from the second stream.

In the manufacture of synthetic boards from cellulosic fibers, a method of blending a binder with the fibers, the method comprising:

• conveying cellulosic fibers in a first stream;
• conveying a binder in a second stream;
• conveying a diluent in a third stream;
• merging the second stream and the third stream to produce a fourth stream;
• immediately thereafter merging the fourth stream and the first stream to apply the binder and the diluent to the fibers;
• and
• flushing the fourth stream at the end of a production run using the third stream after flow of the second stream is stopped.

A method of producing synthetic boards from a cellulosic material, comprising the steps of:

• extracting hot and wet fibers from a cellulosic material;
• transporting the hot and wet fibers in a first stream;
• transporting separate second and third streams comprising a binder and a diluent, respectively, generally toward the first stream;
• merging the second and third streams to form a fourth stream;
• emulsifying the binder and the diluent in the fourth stream;
• immediately after emulsifying, applying the binder/diluent emulsion in the fourth stream to the hot and wet fibers in the first stream;
• partially dewatering the hot and wet fibers;
• forming the partially dewatered fibers into a mat;
• compressing the mat in a heated press to cure the binder to form a consolidated board product;
• and
• flushing the binder/diluent emulsion using the third stream after flow of the second stream is stopped.