Method of manufacturing a fire-retardant treated wood composite panel

Patent metadata

Field	Value
Publication number	US-2025262793-A1
Application number	US-202519055413-A
Country	US
Kind code	A1
Filing date	Feb 17, 2025
Priority date	Feb 15, 2024
Publication date	Aug 21, 2025
Grant date	—

Abstract

A process or method for manufacturing a fire-retardant treated wood composite board or panel, such as oriented-strand board, with a low melting point fire retardant (FR) material, such as boric acid, while the press is operating at typical press temperatures above the FR material melting point. An intervening overlay is applied to the top surface of the mat on the forming line, after the use or application of any FR material within or on the mat, prior to entry into the press. The intervening overlay covers the top surface so as to prevent the melting fire retardant material from contacting the press platen(s). After pressing, the intervening overlay may be removed from the top surface by sanding, buffing, or other methods. The intervening overlay also may be sized so as to extend over one or more edges of the underlying panel, for ease of removal post-process.

First claim

What is claimed is:

1 . A process for manufacturing a fire-retardant treated wood composite board or panel, comprising the steps of:
blending a plurality of wood strands with one or more chemicals or adhesives; apply a fire-retardant material to at least some of said plurality of wood strands; forming, on a forming line, a multi-layer strand mat from said plurality of wood strands, said multi-layer strand mat comprising a top surface; placing an intervening overlay layer on the top surface of the multi-layer strand mat; in a press, applying heat and pressure to the multi-layer strand mat and intervening overlay layer to form a master blank, panel or board; after removing the master blank, panel or board from the press, removing the intervening overlay layer from the top surface.

2 . The process of claim 1 , further comprising the step of adding a fines layer to the multi-layer strand mat as the top surface.

3 . The process of claim 2 , wherein the fines layer comprises fire-retardant material.

4 . The process of claim 1 , further comprising the step of applying a second fire-retardant material to the top surface prior to placing the intervening overlay on the top surface.

5 . The process of claim 1 , wherein the step of removing the intervening overlay layer comprises planing or sanding the intervening overlay layer from the top surface.

6 . The process of claim 1 , wherein the step of removing the intervening overlay layer comprises pressure-washing the intervening overlay layer from the top surface.

7 . The process of claim 1 , wherein the step of removing the intervening overlay layer comprises peeling the intervening overlay layer from the top surface.

8 . The process of claim 7 , wherein the intervening overlay layer comprises an adhesive-resistant coating or layer on the face in contact with the top surface.

9 . The process of claim 1 , wherein the intervening overlay layer and the top surface have a same length and width.

10 . The process of claim 1 , wherein one or more edges of the intervening overlay layer extend beyond a corresponding edge or edges of the top surface.

11 . The process of claim 1 , wherein the intervening overlay layer comprises paper.

12 . The process of claim 1 , wherein the intervening overlay layer comprises kraft paper.

13 . The process of claim 1 , wherein the intervening overlay layer has a thickness of from approximately 1/16 inch to ¼ inch.

14 . The process of claim 1 , wherein the intervening overlay layer has a thickness of from approximately 1/16 inch to 3/16 inch.

15 . The process of claim 1 , wherein the intervening overlay layer has a thickness of 1/16 inch or less.

Assignees

• Louisiana Pacific Corp

Inventors

• Ni Jianwen
• Andrews Chris
• Lucas Dennis

Classifications

• B27N7/005

  Coating boards, e.g. with a finishing or decorating layer · CPC title

• B27N3/12

  from fibres · CPC title

• B27N3/083

  Agents for facilitating separation of moulds from articles · CPC title

• B27N3/04

  from fibres · CPC title

• B27N9/00 Primary

  Arrangements for fireproofing (fireproofing materials C09K21/00) · CPC title