Method and novel composition board products

A process for the continuous production of a composition board comprising;

• (a) separating wood constituents into a first part of wood constituents representing the smallest particle size from a second part of wood constituents representing the larger size wood particles;
• (b) coating said first part of wood constituents with an adhesive to act as an adhesive carrier and binder for said second part of wood constituents;
• (c) leaving said second part of wood constituents in a substantially adhesive free uncoated state;
• and
• (d) blending said first part of wood constituents with said second part of wood constituents.

A method for making composition board comprising:

• (a) separating solid ingredients into a small sized solid component and a large sized solid component;
• (b) adding said small sized solid component to a first blender;
• (c) controlling the viscosity of an adhesive added to said first blender;
• (d) adding 75 percent to 100 percent of adhesive requirements of the final composition board product to said first blender to provide a substantially coated small sized solid component;
• (e) mixing said substantially coated small sized component with said large sized solid component in a second blender to provide a blended composition board having said large sized component substantially uncoated and bound together with said substantially coated small sized component.

A particleboard product comprising an aggregate of large particles substantially uncoated with an adhesive bound together by an aggregate of substantially adhesive coated smaller particles wherein said substantially coated smaller particles are selected from a group of smaller particles consisting of:

• (a) particles having a particle size of about 20 mesh to 40 mesh;
• (b) particles having a particle size of about 40 to 100 mesh;
• and
• (c) particles having a particle size of less than 120 mesh wherein said larger particles are in a range of about 60 to 80 percent by weight of the total composition board product.

A particleboard product comprising:

• (a) an aggregate of larger particles substantially uncoated with an adhesive;
• (b) an aggregate of smaller particles substantially coated with an adhesive;
• and
• (c) an adhesive boundary connecting said larger particles with said smaller particles and comprising from about 2 percent to 15 percent of the surface area as measured along any untreated viewing plane of said particleboard product at 10.times. magnification.

A method for the production of flakeboard comprising:

• (a) separating solid constituents of flakeboard into a fines constituent and a larger flakeboard particles constituent;
• (b) preparing a flakeboard resin carrier by mixing said fines constituent with an adhesive to substantially coat said fines to act as an adhesive carrier for said larger flakeboard particles constituent;
• (c) adding said flakeboard resin carrier to said larger flakeboard particles constituent substantially uncoated with an adhesive;
• and
• (d) mixing said flakeboard resin carrier with said larger flakeboard particles constituent.