Composite product and a process for producing said product

Patent metadata

Field	Value
Publication number	US-10538065-B2
Application number	US-201615571307-A
Country	US
Kind code	B2
Filing date	May 4, 2016
Priority date	May 8, 2015
Publication date	Jan 21, 2020
Grant date	Jan 21, 2020

Abstract

The present invention relates to a composite product comprising a thermally modified solid wood component coated with a layer of a composite material which composite material comprises thermally modified cellulosic material and a polymer. The invention also relates to a process for producing said composite product.

First claim

The invention claimed is:

1. A composite product comprising a thermally modified solid wood component wherein at least one side of the solid wood component is coated with a layer of a composite material which composite material comprises thermally modified cellulosic material and a polymer.

2. The composite product according to claim 1 wherein the composite material comprises less than 50% by weight of thermally modified cellulosic material.

3. The composite product according to claim 1 wherein the thermally modified cellulosic material has a particle size below 1 mm.

4. The composite product according to claim 1 wherein the thermally modified cellulosic material is in the form of a powder.

5. The composite product according to claim 1 wherein the thermally modified cellulosic material is thermally modified microfibrillated cellulose.

6. The composite product according to claim 1 wherein the polymer is a high melt polymer having a melting temperature above 180° C.

7. The composite product according to claim 1 wherein the polymer is polyethylene terephthalate (PET).

8. The composite product according to claim 1 wherein the layer of the composite material has a thickness between 1-5 mm.

9. The composite product according to claim 1 wherein the solid wood component and/or the cellulosic fibers have been thermally modified by heat treatment at a temperature between 160-250° C. at atmospheric pressure.

10. The composite product according to claim 1 wherein two or more sides of the solid wood component have been coated with a layer comprising the composite material.

11. The composite product according to claim 1 wherein the entire solid wood component has been coated with a layer comprising the composite material.

12. The composite product according to claim 1 wherein at least one side of the solid wood component has been coated with more than one layer comprising the composite material.

13. The composite product according to claim 1 , wherein the solid wood component has been surface treated prior to coating with the composite material.

14. The composite product according to claim 13 , wherein the solid wood component has been treated with a fire retardant prior to coating with the composite material.

15. The composite product according to claim 1 , wherein the composite material comprises a flame retardant.

16. Process for producing a composite product which process comprises the steps of:
providing a thermally modified solid wood component,
providing a composite material comprising thermally modified cellulosic material and a polymer,
feeding said composite material to an extruder,
conveying said modified solid wood component through the extruder, and
applying a layer of the composite material to form a coating layer on at least one side of the solid wood component while it is being conveyed through the extruder.

17. Process according to claim 16 , wherein the temperature of the composite material being applied to the solid wood material in the extruder is above 180° C.

18. Process according to claim 16 wherein two or more sides of the solid wood component are being coated with a layer of the composite material.

19. Process according to claim 16 wherein the entire solid wood, i.e. all sides of the product, are being coated with a layer of the composite material.

20. The composite product according to claim 1 wherein the solid wood component and/or the cellulosic fibers have been thermally modified by heat treatment at a temperature between 200-230° C.

21. The composite product according to claim 1 wherein the solid wood component and/or the cellulosic fibers have been thermally modified by heat treatment at a temperature above 120° C. and at elevated pressure.

Assignees

• Stora Enso Oyj

Inventors

• Pynnönen Janne
• Mayes Duncan

Classifications

• B32B27/34

  comprising polyamides · CPC title

• B32B2307/734

  Dimensional stability · CPC title

• B32B2307/3065

  Flame resistant or retardant, fire resistant or retardant · CPC title

• B29C70/12

  using fibres of short length, e.g. in the form of a mat {(non-woven fabrics per se D04H1/00)} · CPC title

• B27K5/0085

  Thermal treatments, i.e. involving chemical modification of wood at temperatures well over 100°C · CPC title