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WO1986002292A1 - Composition d'un agglomere en fibres - Google Patents

Composition d'un agglomere en fibres Download PDF

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Publication number
WO1986002292A1
WO1986002292A1 PCT/US1984/001639 US8401639W WO8602292A1 WO 1986002292 A1 WO1986002292 A1 WO 1986002292A1 US 8401639 W US8401639 W US 8401639W WO 8602292 A1 WO8602292 A1 WO 8602292A1
Authority
WO
WIPO (PCT)
Prior art keywords
fiber board
mixture
pressure
mat
particles
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US1984/001639
Other languages
English (en)
Inventor
Ralph Bullock
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
EGGAN BERNADINE A
MIZE DAVID L
Original Assignee
EGGAN BERNADINE A
MIZE DAVID L
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by EGGAN BERNADINE A, MIZE DAVID L filed Critical EGGAN BERNADINE A
Priority to PCT/US1984/001639 priority Critical patent/WO1986002292A1/fr
Priority to EP19840903857 priority patent/EP0197923A4/fr
Publication of WO1986002292A1 publication Critical patent/WO1986002292A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L97/00—Compositions of lignin-containing materials
    • C08L97/02—Lignocellulosic material, e.g. wood, straw or bagasse
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/0261—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould using ultrasonic or sonic vibrations
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/16—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of fibres, chips, vegetable stems, or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2503/00—Use of resin-bonded materials as filler

Definitions

  • This invention relates to improvements in fiber board products formed, through a number of special processes, from consolidated comminuted Hgnocellulosic materials and, more particularly, to a variety of fiber board products of improved physical characteristics formed by pressure treated comminuted Hgnocellulosic woody materials, adhesive binders and ultrasonic sound. Furthermore, the present invention relates to fiber board compositions comprising pressure treated comminuted lignocellulosic woody material, adhesive binder and specified chemicals to yield, upon consolidation, a variety of structural building products of improved physical characteristics (high strength, fire resistance, water resistance, insect and rot resistance) .
  • U.S. patent No. 4,127,636, issued November 28, 1978, to Flanders discloses a process for making a reinforced board from lignocellulosic particles in which comminuted lignocellulosic particles, binders and other additives and additionally a plurality of elongate reinforcing filaments comprising a plurality of short filaments such as glass fibers or steel wires are distributed uniformly throughout the particle and binder mixture in a random orientation so as to extend generally in all directions.
  • the reinforcing filaments comprise a series of long filaments specifically oriented straightly in a predetermined direction corresponding to the direction of expected tensile strength and in a parallel arrangement spaced transversely from one another.
  • the lignocellulosic particles which can be utilized are preferably woody particles such * as sawdust, bark, etc., but the resultant product can also employ any fibrous lignocellulosic material including various grain and vegetable products such as corn stocks, either alone or in mixture with one or more of the other types of lignocellulosic materials. Additionally, the patent discloses that the ideal ratio of binder to lignocellulosic particles is between about two and six parts of binder to ten parts of particles by weight .
  • crossbanding sheets which are made of a combination of glass fibers and cellulose fibers held together by a synthetic resin binder extending throughout the sheet, the fibers of the crossbanding sheets oriented in a direction perpendicular to the direction of orientation of wood chips or grain of a wood core to which the crossbanding sheets are adhered.
  • the sheets comprise a combination of glass fibers and cellulose fibers in which the glass fibers are present in amounts of 5 to 85% by weight of the total fibers with the cellulosic fibers present in an amount of 95 to 15% of the total fibers. It was found that sheets made with 50 to 75% glass fibers and 50 to 25% ' cellulose fibers have been found to be particularly satisfactory.
  • the binder which is preferably a thermosetting one can constitute about 20 to 60% of the weight of the final sheets.
  • U.S. patent No. 3,880,975 discloses a thin, continuous web produced from a starting material containing at least a major part of defibrated lignocellulose plant substances and a mixture of resinous binding agents amounting to at most 10% of the weight of the final product by first causing the starting materials to form a continuous porously felted fiber mat and subsequently feeding the fiber mat between a pair of cooperating nip-forming press rollers which are heated to a minimum temperature of 160°C, the continuous web thus produced may be subjected to further treatment in order to obtain the required properties.
  • the starting material may include up to one-third of other kinds of fibers such as mineral fibers including asbestos, glass and rockwool fibers; animal textile fibers, vegetable textile fibers. It is further recommended to impregnate the fibers included in the starting materials with small amounts of moisture repellants, fire retarders, fungicides, insect repellants, etc.
  • U.S. patent No. 4,110,397 discloses an improvement in the molding process for composite bodies of sheets, especially those from lignocellulosic material in which an isocyanate binding agent is used, the improvement being the provision of a metallic soap at the interface of the composition and mold surface to assist release.
  • This patent defines ligno ⁇ cellulosic material as wood chips, wood fibers, and the like and/or fibers from other natural products which are lignocellulosic, for example, straw, dried rushes, reeds and grasses and may further include ground nuts and hulls from cereal crops.
  • a fiber board product of improved physical characteristics including strength, fire-resistance, water resistance and insect and rot resistance is formed from a fiber board composition comprising pressure treated comminuted lignocellulosic woody material, a vegetable matter derivative to increase strength, specified chemicals to produce the fire, water, rot and insect resistance of the product, and a synthetic phenolic type resin binder to consolidate the materials into a variety of structural board products.
  • the fiber board products of the present invention are formulated from a fiber board composition which yields the improved properties upon consolidation and allows the manufacture of the improved fiber board products to be accomplished relatively inexpensively such that the formed products can be readily available to the building industry at low cost, even fiber board products having value as structural elements to the building industry.
  • the fiber board compositions of the present invention comprise pressure treated comminuted lignocellulosic woody material, a vegetable matter derivative, specific chemicals and a phenolic type adhesive binder all of which are consolidated into fiber board products of varying size ranging from 2 x 4's to flat sheets that are of comparable strength as natural lumber products and yet are inexpensive, and can be produced in a standard size as substitutes for all shapes and sizes of natural lumber products.
  • lignocellulosic material includes wood chips, wood fibers, shavings, sawdust and the like waste products f om the wood-working industry, and fibrous material from other natural products which are lignocellulosic, for example, hominy feed, which is a mixture of corn bran, corn germ and a part of the starchy portion of corn kernels.
  • hominy feed which is a mixture of corn bran, corn germ and a part of the starchy portion of corn kernels.
  • Lignocellulosic materials disclosed in the above-mentioned patents may also be utilized, but are not preferred because of the increasing strength characteristic of the hominy feed.
  • the fiber board composition comprises 55 to 76% by weight lignocellulosic woody material.
  • the amounts of the lignocellulosic woody ' material will be determined by the use of the -product formed and the physical properties required.
  • the vegetable matter derivative, hominy feed comprises 15 to 25% by weight of the fiber board composition and will be determined by the strength required for a particular application.
  • the wax comprises 1 to 3% by weight
  • the chromated copper arsenate comprises 1 to 1.5% by weight
  • the alumina tri-hydrate comprises 3 to 5% by weight
  • the phenol formaldehyde resin comprises 4 to 10% by weight.
  • the amounts of wax, chromated copper arsenate, alumina tri-hydrate and phenol formaldehyde resin will be determined by specific applications of the consolidated fiber board.
  • phenolic type resin adhesive specifically phenol formaldehyde resin.
  • the phenolic resin is utilized in amounts ranging from 4 to about 10% by dry weight basis of the total composite mixture.
  • Other resins may be used, but phenol formaldehyde resin is preferred because of its benefits in water resistance.
  • Stage 1 of the process includes pressure treatment for a specific amount of time of the individual components of the lignocellulosic woody material of the composite mixture with a chemical compound known as chromated copper arsenate.
  • This particular process has never been accomplished before for fiber board compositions, especially for commercially usable building material.
  • the normal process of pressure impregnation of chromated copper arsenate on natural lumber products is accomplished only after the product has been fabricated. This normal process is not practical or acceptable on fiber board compositions, because of the extremes in swelling during the pressure impregnation process.
  • the adaptation of the normal process to one of pressure impregnating individual components of the lignocellulosic woody material is highly effective, both on softwoods and hardwoods.
  • Stage 2 of the process involves mixing the pressure impregnated chromated copper arsenate lignocellulosic woody material with the vegetable matter derivative, hominy feed, and the chemicals which produce the fire and water resistance.
  • the fire resistance is accomplished by the addition of alumina tri-hydrate (Al 2 0 3 ); partial water resistance by the addition of casco wax; and the rot and insect resistance by the already pressure impregnated chromated copper arsenate lignocellulosic woody material.
  • the chemicals and vegetable matter are mixed with the dried lignocellulosic woody material in a container or drum, which produces a tumbling action, thereby assuring even distribution of all component parts throughout the composite mixture.
  • Stage 3 is the consolidation phase of the process.
  • the dried composite mixture from stage 2 is transferred to another container or drum for final tumbling prior to being laid out in mats for pressing.
  • the composite mixture is sprayed with a phenol formaldehyde resin, usually 6% by dry weight of the total composite mixture, until the mixture is thoroughly saturated with the resin. When this point is reached, the composite mixture is then ready to be formed up into mats for pressing.
  • the consolidation of the composite mixture into fiber board products is accomplished by hot pressing at temperatures of about 320° to 360°F, pressures at about 400 to about 600 psi for about 3 to about 5 minutes.
  • Normal press time duration is about 15 minutes, but by utilizing ultra sonic sound of about 3.6 to about 3.7 mega hertz (million cycles per second) to speed curing time of the mats, the press time duration can be reduced from 300 to about 55% and result in a product that has a uniform density throughout, thereby creating a stronger and more usable material.
  • Another object of the invention is to provide a lignocellulosic fiber board composition which can be consolidated into a variety of fiber board products of improved strength and sufficient fire, water, rot and insect resistance at costs which allow the products to be readily available to the building industry.
  • a fiber board in accordance with the present invention is manufactured by adding to a mixture of chromated copper arsenate impregnated wood particles, a vegetable matter derivative, hominy feed and specific chemicals to produce fire and water resistance, a phenolic type resin adhesive binder, phenol formaldehyde resin, followed by subjecting the mixture * to heat, pressure and ultrasonic sound to consolidate the composite mixture into the desired fiber board shape.
  • the process involves selecting the required amount of wood chips, softwood or hardwood, not to exceed 1/16 inch diameter, and other wood waste, specifically sawdust * .
  • This material is loaded into a retort pressure cylinder, in a specially constructed perforated cylinder capable of holding the small size material used for the mix.
  • the retort is sealed and a vacuum is drawn on the entire cylinder.
  • the chromated copper arsenate is introduced until the retort is full and a pressure of 120 to 125 psi, pounds per square inch, is introduced.
  • the normal time duration for natural lumber is from 10 to about 30 minutes, depending on the quantity of heartwood present in the fabricated material. Heartwood will not impregnate to any great degree when part of a fabricated piece of natural lumber material. This poses no great problem in the composite mix, because of the particle size, so the low end of the time spectrum is sufficient for impregnating the wood particles of the mix.
  • the lignocellulosic woody material After the lignocellulosic woody material is fully impregnated, it is removed from the retort and transferred to drying kilns.
  • the temperatures are strictly regulated and drawn up slowly to a maximum temperature of 180°F over a period of 6 to 8 hours, to prevent warping and twisting. After the maximum temperature is reached, it is held for about 48 to about 72 hours.
  • This entire drying cycle can be altered using the lignocellulosic woody material, because there is no warping or twisting possible on such small pieces of wood.
  • the maximum of 180°F can be accomplished extremely fast with no detrimental effect, and the total drying time can be reduced substantially down to 48 hours maximum.
  • stage 2 This yields a mix of about 5 to 12% moisture, and is now ready to go to stage 2, which is the primary mixing phase.
  • stage 2 PRIMARY MIXING PHASE
  • This stage of the process involves the mixing of all the components that go together to form the fiber board product with the exception of the adhesive resin binder. That includes the chromated copper arsenate impregnated lignocellulosic woody material; the vegetable matter derivative.
  • OMPI hominy feed the fire retardant chemical, alumina tri-hydrate; and the water retardant agent, casco wax. These components all perform in a specified way to produce the desired result.
  • the chromated copper arsenate makes the wood chips and sawdust insect and rot resistant by making the food supply, the wood fiber itself, unpalatable to the insects and rot.
  • the vegetable matter derivative, hominy feed which is a mixture of corn bran, corn germ and a part of the starchy portion .of the corn kernels, is a by-product of the dry corn milling industry. This hominy feed, when heated beyond 300°F, which the temperature for pressing fiber board always exceeds, becomes a very high viscosity liquid when mixed with the adhesive binder.
  • the hominy feed acts as a secondary binder and tends to create a much stronger end product.
  • the alumina tri-hydrate (A1 2 0 3 ), in the form of a low viscosity powder, is a combination of 65% alumina tri-hydrate and 35% calcium carbonate. It * acts as a fire retardant through the use of a specified temperature release point. When the temperature reaches 400°F, the release point is reached, thereby releasing water vapor, which tends to impede fire movement.
  • the casco wax when mixed in the composite mixture, with the phenol formalde ⁇ hyde resin together form a portion of the water retardant capability of the fiber board.
  • the dried lignocellulosic woody material, vegetable matter and chemicals are mixed together in a large container or drum, which produces a tumbling action, thereby assuring even distribution of all component parts throughout the composite mixture.
  • the material after mixing is monitored by a radioactive device, which ensures the correct density is maintained prior to pressing.
  • the primary mixing phase is completed and the mixture is ready to go into the final mixing phase, which includes the introduction of the phenol formaldehyde resin just prior to board consolidation.
  • This final stage of the process consists of adding the phenol formaldehyde resin to the composite and consolidation of the resin-charged mixture.
  • the dried composite mixture from the primary mixing stage is transferred to another container or drum adjacent to the press for charging with resin.
  • the mixture is tumbled at a relatively low speed while being sprayed with a 4 to about 10% mixture of phenol formaldehyde resin (6% is normal). It continues to be tumbled until the composite is fully saturated with resin. At this time, the composite is transferred to a hopper, which lays out the mat prior to pressing.
  • the consolidation is accomplished by hot pressing the mixture at a temperature of about 320° to 360°F and a pressure of about 500 to about 600 psi.
  • the utilization of ultrasonic sound equipment allows temperatures at the low end of the spectrum to be used and allows
  • press time duration to be reduced significantly. Because the sound frequency levels used are in the 3.6 to about 3.7 mega hertz (million cycles per second) range, heat is produced which causes the phenol formaldehyde resin to cure more evenly and quickly throughout the entire board and not just on the outer skin.
  • the time on a normal press cycle is about 15 minutes, but through the use of high frequency the time can be reduced down to about 3 to 5 minutes, which is a reduction of from 300 to
  • the board is removed from the press and allowed to cool to a temperature below 100°F.
  • the board is sprayed with a penetrating type petroleum distillate, which is composed of 10% solids and 90% mineral spirits.
  • the reason for letting the board cool below 100°F is because the compound has a flash point of 104°F. What this compound does is to permanently seal one side of the board from moisture entry for use in exterior type situations.

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  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Architecture (AREA)
  • Health & Medical Sciences (AREA)
  • Civil Engineering (AREA)
  • Forests & Forestry (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Oral & Maxillofacial Surgery (AREA)
  • Thermal Sciences (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)

Abstract

Composition d'aggloméré en fibres et plaque composite en fibre ainsi formée pouvant être façonnée et donner après durcissement une variété de produits structuraux de construction allant des feuilles plates et des panneaux pouvant s'emboîter, de dimensions modulaires, aux éléments de 2 x 4 ou 2 x 12, etc. La composition d'aggloméré en fibres comprend des particules lignocellulosiques telles que des particules de déchets de bois tendre ou de bois dur, qui ont été imprégnées sous-pression, avec un produit chimique, tel que l'arséniate de cuivre chromé, pour résister aux insectes et à la pourriture; avec un dérivé de matières végétales, telles que les restes de balles de graminées, pour en augmenter la résistance; avec un produit chimique retardant le feu, tel que du tri-hydrate d'alumine; avec un produit chimique retardant l'eau, tel qu'une cire de casco. On provoque ensuite le durcissement de la structure d'aggloméré en fibres ainsi façonnée en utilisant entre 4 et 10% environ en poids d'une résine du type phénolique, avec des pressions entre 400 et 600 psi environ, une chaleur entre 320 et 360oF environ et des vibrations ultrasoniques dont la fréquence est comprise entre 3,6 et 3,7 MH2.
PCT/US1984/001639 1984-10-11 1984-10-11 Composition d'un agglomere en fibres Ceased WO1986002292A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
PCT/US1984/001639 WO1986002292A1 (fr) 1984-10-11 1984-10-11 Composition d'un agglomere en fibres
EP19840903857 EP0197923A4 (fr) 1984-10-11 1984-10-11 Composition d'un agglomere en fibres.

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US1984/001639 WO1986002292A1 (fr) 1984-10-11 1984-10-11 Composition d'un agglomere en fibres

Publications (1)

Publication Number Publication Date
WO1986002292A1 true WO1986002292A1 (fr) 1986-04-24

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1984/001639 Ceased WO1986002292A1 (fr) 1984-10-11 1984-10-11 Composition d'un agglomere en fibres

Country Status (2)

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EP (1) EP0197923A4 (fr)
WO (1) WO1986002292A1 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1992012836A1 (fr) * 1991-01-23 1992-08-06 Aci Australia Limited Substrat de construction et son procede de fabrication
US8696958B1 (en) 2006-08-21 2014-04-15 Flowery Branch Molded composite manufacturing process and products thereof
CN105432951A (zh) * 2015-05-26 2016-03-30 上海美桥科材料科技有限公司 一种水溶性减震泡沫及其制备方法
SE2351056A1 (en) * 2023-09-11 2025-03-12 Blue Ocean Closures Ab Method of producing fiber product from natural fibers using pressure and vibration

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4479912A (en) * 1981-10-20 1984-10-30 Bernadine A. Eggan Fiber board composition

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3668286A (en) * 1970-04-14 1972-06-06 Miller Hofft Inc Fiberboard produced from wood particles having a 5 to 25 percent moisture content prior to steaming and mechanical reduction in the formation process
US3927235A (en) * 1974-03-18 1975-12-16 Poo Chow Reconstituted board products from plant-fiber residues
US4247329A (en) * 1980-03-27 1981-01-27 Koppers Company, Inc. Water repellent aqueous wood concentrates
US4405542A (en) * 1982-01-25 1983-09-20 Greer Marian B Method for the production of a composite material

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4479912A (en) * 1981-10-20 1984-10-30 Bernadine A. Eggan Fiber board composition

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See also references of EP0197923A4 *

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1992012836A1 (fr) * 1991-01-23 1992-08-06 Aci Australia Limited Substrat de construction et son procede de fabrication
US8696958B1 (en) 2006-08-21 2014-04-15 Flowery Branch Molded composite manufacturing process and products thereof
US9056444B1 (en) 2006-08-21 2015-06-16 David William Moeller Molded composite products, including solid doors
CN105432951A (zh) * 2015-05-26 2016-03-30 上海美桥科材料科技有限公司 一种水溶性减震泡沫及其制备方法
SE2351056A1 (en) * 2023-09-11 2025-03-12 Blue Ocean Closures Ab Method of producing fiber product from natural fibers using pressure and vibration
SE547882C2 (en) * 2023-09-11 2025-12-16 Blue Ocean Closures Ab Method of producing fiber product from natural fibers using pressure and vibration

Also Published As

Publication number Publication date
EP0197923A1 (fr) 1986-10-22
EP0197923A4 (fr) 1988-06-20

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