Composite article and method of making same
AssigneeMasonite Corporation
InventorsJohn Peter Walsh, Allen R. Hill, Thomas M. Ruffin
Life of this patent
Estimating the term…
Abstract
Disclosed herein is a cellulosic composite article and steam injection press methods of making the same by combining a phenolic resin with cellulosic material to form a mixture and, thereafter, providing a catalyzing agent, such as aluminum chloride, to the mixture. As an alternative, the method may include the steps of combining a catalyzing agent with a cellulosic material to form a mixture and, thereafter, providing a phenolic resin to the mixture. The method further includes the steps of forming a mat from the catalyzing agent-containing mixture and consolidating the catalyzing agent-containing mat in a pressing apparatus under heat, steam, and pressure to form the consolidated cellulosic product.
Claims9
A method of making a cellulosic composite article, the method comprising the steps of:
- (a) combining a phenolic resin with cellulosic material to form a mixture;
- (b) forming a mat from the mixture of step (a);
- (c) consolidating the mat under heat, steam, and pressure in a pressing apparatus to form the article;
- and,
- (d) providing an aqueous solution of aluminum chloride to the mixture prior to step (c), wherein said solution provides about 0.2 weight percent to about 0.6 weight percent aluminum chloride based on the total weight of the mixture of step (a).
A method of making a cellulosic composite article, the method cop rising the steps of:
- (a) combining aluminum chloride with cellulosic material to form a mixture;
- (b) forming a mat from the mixture of step (a);
- (c) consolidating the mat under heat, steam, and pressure in a pressing apparatus to form the article;
- and,
- (d) providing a phenolic resin to the mixture prior to step (c),
- wherein of step (a) comprises combining about 0.2 weight percent to 0.6 weight percent aluminum chloride based on the total weight of the cellulosic material and resin.
A method of making a cellulosic composite article, the method comprising the steps of:
- (a) combining a phenolic resin with cellulosic material to form a mixture, the cellulosic material comprising polymeric molecules;
- (b) forming a mat form the mixture of step (a);
- (c) consolidating the mat under heat, steam, and pressure in a pressing apparatus to form the article;
- and,
- (d) providing a catalyzing agent comprising aluminum chloride,to the mixture prior to step (c) to acid hydrolyze the polymeric molecules present in the cellulosic material.
Dependencies are inferred from the claim text.