Method for making composite board using phenol formaldehyde binder
OwnerBrian Bonomo, Pete Walsh +3inventors
InventorsBrian Bonomo, Pete Walsh, Kelly Seifert, Alex Vergara, Michelle Merrell
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Abstract
Wood composite boards are produced from a wood fiber treated with a slow curing, low alkalinity phenol formaldehyde (PF) resin. The resin treated wood fiber is consolidated and cured in a press using steam injection. The slow curing nature of the resin prevents pre-cure of the resin. The press using steam injection speeds curing so that boards can be produced in press cycles comparable to the curing of wood fiber treated with other resins in a press with no steam injection.
Claims15
A method for making a composite wood product, comprising the steps of:
- forming a mat comprising wood particles treated with an uncured, slow-curing phenol formaldehyde binder, the binder having an alkalinity less than 2.5% and a pH less than 10;
- consolidating the mat;
- supplying a quantity of steam to the mat at a pressure and for a period of time sufficient to cure the binder;
- and
- venting excess pressure from the mat.
A method for making a composite wood product, comprising the steps of:
- forming a mat comprising wood particles treated with an uncured, slow-curing phenol formaldehyde binder, the binder having an alkalinity less than 2.5% and a pH less than 10;
- placing said mat in a press cavity defined between first and second press platens;
- sealing the press cavity;
- consolidating the mat by moving at least one of the first and second press platens toward the other of the first and second press platens;
- supplying a quantity of steam to the mat through at least one steam port, said quantity of steam supplied at a pressure and for a period of time sufficient to cure the binder;
- venting excess pressure from the mat before unsealing the press cavity;
- and
- opening the press cavity.
A method for making a composite wood product, comprising the steps of:
- forming a mat comprising wood particles treated with an uncured slow-curing phenol formaldehyde binder, the binder having an alkalinity less than 2.5% and a pH less than 10;
- placing said mat in a press cavity defined between first and second press platens;
- closing the press cavity;
- consolidating the mat fully by moving at least one of the first and second press platens toward the other of the first and second press platens to a final compression position;
- supplying a first quantity of steam to the mat through at least one steam port in the first press platen, said first quantity of steam supplied at a pressure in the range of 25 to 75 psi and for a period of time in the range of 30 to 120 seconds;
- venting said first quantity of steam from the mat through said at least one steam port in said first press platen such that excess air is purged from the mat;
- supplying a second quantity of steam to the mat through the at least one steam port in the first press platen, the second quantity of steam supplied at a pressure in the range of 100 to 250 psi and at a temperature sufficient to cure the binder;
- venting excess pressure from the mat before opening the press cavity;
- and
- opening the press cavity.
A method for making a composite wood product, comprising the steps of:
- forming a mat comprising wood particles treated with an uncured, slow-curing phenol formaldehyde binder, the binder having an alkalinity less than 2.5% and a pH less than 10;
- preheating the mat;
- consolidating the mat in a press cavity;
- and
- supplying a quantity of steam to the mat at a pressure and a temperature and for a period of time sufficient to cure the binder.
Dependencies are inferred from the claim text.