Molded thin-layer lignocellulose composites having reduced thickness and methods of making same
AssigneeJELD-WEN, Inc.
InventorsRandy Jon Clark, Michael Jay Henry
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Abstract
Thin-layer lignocellulose composites having reduced thickness and methods for the manufacture of such thin-layer composites are disclosed. Also described is a process for making wood-based composite door skins of reduced thickness. The door skins may be less than 0.115 inches (2.92 mm) thick.
Claims28
A method for making a molded thin-layer composite of reduced thickness comprising the steps of:
- forming a mixture comprising a refined lignocellulosic fiber, a resin, and a wax selected from the group consisting of paraffin wax, microcrystalline wax, shellac wax, ozokerite wax, montan wax, slack wax, emulsified waxes thereof, and combinations thereof;
- pre-pressing the mixture into a loose mat;
- coating at least one of two dies with an anti-bonding agent including a ceramic layer;
- and
- pressing the mat between the two dies at an elevated temperature and pressure and for sufficient time to form a thin-layer lignocellulosic composite comprising a thickness from about 0.063 inches (1.60 mm) to 0.115 inches (2.92 mm).
A method for making a door skin of reduced thickness comprising the steps of:
- forming a mixture comprising a refined lignocellulosic fiber, a resin, and a wax selected from the group consisting of paraffin wax, microcrystalline wax, shellac wax, ozokerite wax, montan wax, slack wax, emulsified waxes thereof, and combinations thereof;
- pre-pressing the mixture into a loose mat;
- coating at least one of two dies with an anti-bonding agent including a ceramic layer;
- and
- pressing the mat between the two dies at an elevated temperature and pressure and for sufficient time to form a thin-layer lignocellulosic composite door skin comprising a thickness from about 0.063 inches (1.60 mm) to 0.115 inches (2.92 mm).
A method for making a molded thin-layer composite of reduced thickness comprising the steps of:
- forming a mixture comprising a refined lignocellulosic fiber, a resin, and a wax selected from the group consisting of paraffin wax, microcrystalline wax, shellac wax, ozokerite wax, montan wax, slack wax, emulsified waxes thereof, and combinations thereof;
- pre-pressing the mixture into a loose mat;
- coating at least one of two dies with an anti-bonding agent including fluorocarbons;
- and
- pressing the mat between the two dies at an elevated temperature and pressure and for sufficient time to form a thin-layer lignocellulosic composite comprising a thickness from about 0.063 inches (1.60 mm) to 0.115 inches (2.92 mm).
A method for making a door skin of reduced thickness comprising the steps of:
- forming a mixture comprising a refined lignocellulosic fiber, a resin, and a wax selected from the group consisting of paraffin wax, microcrystalline wax, shellac wax, ozokerite wax, montan wax, slack wax, emulsified waxes thereof, and combinations thereof;
- pre-pressing the mixture into a loose mat;
- coating at least one of two dies with an anti-bonding agent including fluorocarbons;
- and
- pressing the mat between the two dies at an elevated temperature and pressure and for sufficient time to form a thin-layer lignocellulosic composite door skin comprising a thickness from about 0.063 inches (1.60 mm) to 0.115 inches (2.92 mm).
Dependencies are inferred from the claim text.