Wood veneers and products therefrom having enhanced strength and stiffness

A method of producing a compacted springback-resistant wood veneer, the veneer having a major surface, the method comprising:

• (a) compacting at least a portion of a major surface of the veneer;
• (b) impregnating at least a portion of the compacted portion of the major surfaces of the veneer with a liquid thermosettable resin at a loading level which does not saturate the veneer;
• and
• (c) curing the resin while the compacted portion of the veneer is maintained compacted, so as to form a cured resin that causes the impregnated compacted portion of the major surface to resist springback.

A method for producing a wood product having enhanced strength and stiffness levels, the method comprising:

• (a) providing a wood veneer comprising wood cells, the veneer having first and second major surfaces across which extend length and width dimensions of the veneer, a thickness dimension, a first density level, a first strength level, and a first stiffness level;
• (b) applying to at least one major surface of the veneer a liquid thermosettable resin capable of being absorbed into the wood cells and capable of being cured to form a rigid thermoset material, wherein the resin is applied to the major surface at a loading level within a range of L1 to L2 shown in FIG. 1;
• (c) compacting the veneer in the thickness dimension so as to cause wood cells into which the resin has absorbed to undergo a deformation sufficient to reduce the thickness dimension and thus densify the veneer to a level above the first density level and cause increases in strength and stiffness of the veneer to levels above the first strength and stiffness levels, respectively;
• and
• (d) while maintaining compaction of the veneer, curing the resin applied to the veneer to form the resin into a rigid thermoset material capable of retaining compaction of the veneer.

A method for producing a wood product having enhanced strength and stiffness levels, the method comprising:

• (a) providing a wood veneer comprising wood cells, the veneer having first and second major surfaces across which extend length and width dimensions of the veneer, a thickness dimension, a first density level, a first strength level, and a first stiffness level;
• (b) applying to at least one major surface of the veneer a liquid thermosettable resin capable of being absorbed into the wood cells and capable of being cured to form a rigid thermoset material, wherein the resin is applied to the major surface at a loading level sufficient to penetrate into the thickness dimension no more than about 10 cells deep without saturating the veneer with resin;
• (c) compacting the veneer in the thickness dimension so as to cause wood cells into which the resin has absorbed to undergo a deformation sufficient to reduce the thickness dimension and thus densify the veneer to a second density level above the first density level and cause increases in strength and stiffness of the veneer to levels above the first strength and stiffness levels, respectively;
• and
• (d) while maintaining compaction of the veneer, curing the resin applied to the veneer to form the resin into a rigid thermoset material capable of retaining compaction of the veneer.

A method for producing a strength-enhanced wood product, the method comprising:

• (a) providing a wood veneer comprising wood cells, the veneer having first and second major surfaces across which extend length and width dimensions of the veneer, and a thickness dimension, the veneer having a capability of being compacted, up to a maximal degree, in the thickness dimension so as to form a surficial stratum of compacted wood cells on at least one major surface and extending to a depth into the thickness dimension, the maximal degree of compaction representing an amount of compaction above which the veneer would not exhibit an incremental increase in strength with a corresponding increase in compaction;
• (b) applying to a major surface of the veneer a liquid thermosettable resin capable of being absorbed into the wood cells of the veneer and capable of being cured to form a rigid thermoset material, wherein the resin is applied at a non-saturating loading level sufficient for the resin to penetrate from the major surface into the thickness dimension no more than the depth of the surficial stratum that would be formed if the veneer were compacted at the maximal degree;
• (c) allowing the resin to penetrate into the veneer;
• (d) compacting the veneer in the thickness dimension an amount no greater than the maximal degree so as to form the surficial stratum of compacted cells on the major surface and thereby reduce the thickness dimension of the veneer;
• and
• (e) while maintaining compaction of the veneer, curing the resin applied to the veneer to form the resin into a rigid thermoset material capable of retaining compaction of the veneer.