Method of manufacturing a wood-based board

Patent metadata

Field	Value
Publication number	US-10569452-B2
Application number	US-201414305251-A
Country	US
Kind code	B2
Filing date	Jun 16, 2014
Priority date	Jun 17, 2013
Publication date	Feb 25, 2020
Grant date	Feb 25, 2020

Abstract

A method of manufacturing a wood-based board (10). The method includes applying at least one first fibre mat (11) including a first mix comprising lignocellulosic particles and a binder on a carrier (13), applying a second fibre mat (12) including a second mix including cellulosic particles and a binder on said at least one first fibre mat (11), and pressing said at least one first fibre mat (11) into a base layer (14) and the second fibre mat (12) into a surface layer (15) simultaneously, thereby forming a wood-based board (10). Also, to such a wood-based board (10).

First claim

The invention claimed is:

1. A method of manufacturing a wood-based board, comprising:
applying at least one first fibre mat, comprising a first mix comprising lignocellulosic particles and a first binder, on a conveyor belt,
applying a second fibre mat, comprising a second mix comprising cellulosic particles and a second binder, on said at least one first fibre mat, and
pressing said at least one first fibre mat into a base layer and the second fibre mat into a surface layer simultaneously using a hot press, thereby forming a wood-based board,
wherein the cellulosic particles of the second mix possess less than 5% lignin.

2. The method according to claim 1 , wherein the step of pressing comprises simultaneously adhering said base layer and the surface layer to each other.

3. The method according to claim 1 , wherein the step of pressing said at least one fibre mat and the second fibre mat using the hot press comprises applying heat and pressure, and wherein pressure and/or binder content of the second fibre mat are chosen such that the surface layer remains opaque after curing.

4. The method according to claim 1 , wherein the step of pressing comprises curing said at least one first fibre mat into the base layer and the second fibre mat into the surface layer simultaneously.

5. The method according to claim 1 , further comprising printing a print on the second fibre mat before pressing.

6. The method according to claim 1 , further comprising printing a print on the surface layer after pressing.

7. The method according to claim 1 , further comprising applying a protective layer on the surface layer.

8. The method according to claim 1 , wherein the cellulosic particles of the second mix are at least partially bleached.

9. The method according to claim 1 , wherein the lignocellulosic particles of the first mix are refined wood fibres, wood chips, unrefined wood fibres, wood strands, or saw dust.

10. The method according to claim 1 , wherein the first binder is a thermosetting resin.

11. The method according to claim 1 , wherein the second binder is a thermosetting resin.

12. The method according to claim 1 , wherein the wood-based board is a MDF or HDF.

13. The method according to claim 1 , wherein the wood-based board is a particle board or an oriented strand board.

14. The method according to claim 1 , wherein
the lignocellulosic particles of the first mix are between 1 and 10 mm in length and are between 0.1 and 1 mm in width, and
the cellulosic particles are between 50 and 3000 μm in length and are between 0.1 and 1 mm in width.

15. The method according to claim 1 , wherein the lignocellulosic particles are wood chips, the wood chips possessing a length of about 100 mm, a width between 10 and 20 mm, and a thickness of less than 1 mm.

16. The method according to claim 1 , wherein the surface layer of the wood-based board is pale to white in color.

17. The method according to claim 1 , wherein the surface layer of the wood-based board has a white grade of more than 80 on a Berger color scale.

18. The method according to claim 1 , wherein the pressing using the hot press is performed at a pressure below a predetermined threshold such that the surface layer is opaque after removing the pressure.

19. The method according to claim 18 , wherein the predetermined threshold is configured such that the surface layer contains air pockets after the wood-based board is formed.

20. The method according to claim 19 , wherein the surface layer has an opacity of at least 80%.

21. A method of manufacturing a wood-based board, comprising:
applying at least one first fibre mat comprising a first mix comprising lignocellulosic particles and a first binder on a conveyor belt,
applying a surface layer comprising cellulosic particles on said at least one first fibre mat prior to pressing the at least one first fibre mat, and
pressing the surface layer to said at least one first fibre mat using a hot press, thereby adhering the surface layer to said at least one first fibre mat and forming a wood-based board,
wherein the cellulosic particles of the surface layer possess less than 5% lignin.

22. The method according to claim 21 , wherein the surface layer comprises a sheet.

23. The method according to claim 21 , wherein the surface layer comprises a second fibre mat comprising cellulosic particles and a second binder.

24. The method according to claim 21 , wherein pressing comprises curing said at least one first fibre mat into a base layer.

25. The method according to claim 21 , further comprising printing a print on the surface layer before or after pressing.

26. The method according to claim 21 , wherein the first binder is a thermosetting binder.

27. A method of manufacturing a wood-based board, comprising:
applying at least one first fibre mat, comprising a first mix comprising lignocellulosic particles and a first binder, on a carrier,
applying a second fibre mat, comprising a second mix comprising cellulosic particles and a second binder, on said at least one first fibre mat, and
pressing said at least one first fibre mat into a base layer and the second fibre mat into a surface layer simultaneously using a hot press, thereby forming a wood-based board,
wherein the cellulosic particles of the second mix possess less than 5% lignin, and
wherein the second mix is pigment free.

28. The method according to claim 27 , wherein the carrier is a conveyor belt.

Assignees

• Vaelinge Innovation Ab
• Valinge Innovation Ab

Inventors

• Vetter Georg
• Håkansson Niclas
• Bergelin Marcus
• Persson Hans

Classifications

• Y10T428/253

  Cellulosic [e.g., wood, paper, cork, rayon, etc.] · CPC title

• Y10T428/31982

  Wood or paper · CPC title

• E04C2/16 Primary

  of fibres, chips, vegetable stems, or the like · CPC title

• B29K2001/00

  Use of cellulose, modified cellulose or cellulose derivatives, e.g. viscose, as moulding material · CPC title

• B29C2795/007

  after shaping · CPC title