Method of producing coating on reconstituted wood substrate

A method of producing a coating on the surface of a reconstituted wood substrate comprising:

• foaming a polymerized latex emulsion comprising:
• polymer particles of a polymer of an ethylenically unsaturated monomer, said polymer having T.sub.g in the range of 10.degree. C. to 100.degree. C.,
• a foaming agent, and
• a foam stabilizer, said foam stabilizer being in the range of 0.1 to 15 percent by weight of emulsion solids;
• applying a layer of said foamed polymerized latex emulsion on the surface of said reconstituted wood substrate;
• drying said foamed layer into a hardened layer;
• crushing said hardened layer;
• and
• curing said crushed layer to form said coating on said reconstituted wood substrate.

A method of producing a coated reconstituted wood substrate comprising:

• mixing a binder with wood particles, wood chips, wood fibers or wood flakes to form a wood/binder mix;
• dispensing said wood/binder mix to produce a mat on a conveying surface;
• foaming a polymerized latex emulsion comprising:
• polymer particles of a polymer of an ethylenically unsaturated monomer, said polymer having T.sub.g in the range of 10.degree. C. to 100.degree. C., and
• a foaming agent;
• applying a foamed layer of said foamed polymerized latex emulsion on a surface of said mat;
• drying said foamed layer into a hardened layer;
• crushing said hardened layer;
• and
• curing said crushed layer and said mat into said coated reconstituted wood substrate.

A method of producing a coated reconstituted wood substrate comprising:

• mixing a binder with wood particles, wood chips, wood fibers or wood flakes to form a wood/binder mix;
• dispensing said wood/binder mix on a conveying surface to produce a mat;
• foaming a polymerized latex emulsion comprising:
• polymer particles of a polymer of an ethylenically unsaturated monomer, said polymer having T.sub.g in the range of 10.degree. C. to 100.degree. C.,
• a foaming agent, and
• a foam stabilizer, said foam stabilizer being in the range of 0.1 to 15 percent by weight of emulsion solids;
• applying a foamed layer of said foamed polymerized latex emulsion on a surface of said mat;
• drying said foamed layer into a hardened layer;
• crushing said hardened layer;
• and
• curing said crushed layer and said mat into said coated reconstituted wood substrate.

A method of producing a coating on the surface of a reconstituted wood substrate comprising:

• air whipping a polymerized latex emulsion into a foam having a foam density in the range of 0.04 to 0.25 grams per milliliters, said polymerized latex emulsion comprising from 10 percent to 60 percent by weight of polymer particles of a polymer of an ethylenically unsaturated monomer and having Tg in the range of 10.degree. C. to 100.degree. C., from 0 percent to 40 percent by weight of emulsion solids of an aminoplast resin crosslinking agent, from 1 percent to 15 percent by weight of said emulsion solids of a foaming agent, from 0 percent to 10 percent by weight of said emulsion solids of a wetting agent, and from 0 percent to 15 percent by weight of said emulsion solids of a foam stabilizer selected from the group consisting of disodium N-octadecylsulfosuccinate, tetrasodium N-(1,2-dicarboxyethyl)-N-octadecylsulfosuccinate, sulfosuccinimate surfactant, diamyl ester of sodium sulfosuccinic acid, dihexyl ester of sodium sulfosuccinic acid, dioctyl ester of sodium sulfosuccinic acid, distearyl pyridinium chloride, N-coco-beta-aminopropionic acid and the sodium salts of said distearyl pyridinium chloride and N-coco-beta-aminopropionic acid;
• applying a layer of said foamed polymerized latex emulsion on a surface of said reconstituted wood substrate to a thickness in the range of 0.8 to 10 mms;
• drying said foamed layer at a drying temperature in the range of 40.degree. C. to 180.degree. C. for a drying time in the range of 6 hours to 30 seconds, respectively, into a hardened layer;
• crushing said hardened layer at a crushing pressure in the range of 0.1 to 3.5N/mm.sup.2 ;
• and
• curing said crushed layer at a cure temperature in the range of 24.degree. C. to 287.degree. C. to form said coating on said reconstituted wood substrate.

A method of producing a coating on the surface of a reconstituted wood substrate comprising:

• foaming a polymerized latex emulsion comprising:
• polymer particles of a polymer of an ethylenically unsaturated monomer, said polymer having T.sub.g in the range of 10.degree. C. to 100.degree. C., and
• a foaming agent;
• applying a layer of said foamed polymerized latex emulsion on the surface of said reconstituted wood substrate;
• drying said foamed layer into a hardened layer;
• and
• simultaneously crushing and curing said hardened layer to form said coating on said reconstituted wood substrate.

A method of producing a coated reconstituted wood substrate comprising:

• mixing a binder with wood particles, wood chips, wood fibers or wood flakes to form a wood/binder mix;
• dispensing said wood/binder mix to produce a mat on a conveying surface;
• foaming a polymerized latex emulsion comprising:
• polymer particles of a polymer of an ethylenically unsaturated monomer, said polymer having T.sub.g in the range of 10.degree. C. to 100.degree. C., and
• a foaming agent;
• applying a foamed layer of said foamed polymerized latex emulsion on a surface of said mat;
• drying said foamed layer into a hardened layer;
• simultaneously crushing and curing said hardened layer to form a coating on said reconstituted wood substrate.