Resin starved impregnated panels, wood composites utilizing said panels and methods of making the same

A wood composite comprising;

• at least one wooden member having two surfaces disposed in substantially parallel relation to one another;
• at least one resin starved panel disposed at a predetermined location adjacent said at least one wooden member;
• and
• a bonding adhesive disposed between said surfaces of said at least one wooden member and said at least one resin starved panel to bond said surfaces together;
• wherein said resin starved panel has two surfaces and four edges and comprises;
• a center portion having a core and two surfaces, said center portion comprising a plurality of fibers bound together by a predetermined resin such that said surfaces of said center portion contain significantly less resin than said core;
• a layer of an impregnating adhesive bonded to each surface of said center portion;
• and
• at least one sacrificial edge disposed along at least one of said plurality of edges of said panel;
• wherein said impregnating adhesive has similar chemical properties to chemical properties of said bonding adhesive such that a physico-chemical bond is formed between said impregnating adhesive and said predetermined bonding adhesive;
• and
• wherein said impregnating adhesive is not said predetermined resin.

A method of manufacturing a wood composite, said method comprising the steps of:

• forming a resin starved impregnated panel, said forming step comprising the steps of:
• forming a center portion having a pair of resin starved surfaces;
• impregnating said resin starved surfaces with an impregnating adhesive;
• removing a portion of said impregnating adhesive to form a substantially smooth flat surface;
• curing a remaining portion of said impregnating adhesive to a desired degree;
• and
• bonding a pair of sacrificial edges to said panel;
• disposing said resin starved impregnated panel against at least one wooden member;
• and
• bonding said panel and said at least one wooden member together to form a wood composite.