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LIGNOCELLULOSIC COMPOSITE ARTICLE

IP.com Disclosure Number: IPCOM000246234D
Publication Date: 2016-May-18

Publishing Venue

The IP.com Prior Art Database

Abstract

[0001] The present disclosure provides a composite article comprising a plurality of lignocellulosic pieces, a plurality of fibers, and a binder component. Each of fibers has a width to length aspect ratio of at least 1:100. The plurality of fibers maintains orientation of the plurality of lignocellulosic pieces during manufacture of the composite article. [0002] The present disclosure further provides a method of forming the composite article. The method comprises the step of combining the binder component and the plurality of lignocellulosic pieces. The method further comprises the step of combining the plurality of fibers and the plurality of lignocellulosic pieces. The method also comprises the step of disposing the plurality of lignocellulosic pieces having the binder component and the plurality of fibers combined therewith on a carrier to form a mass. The method still further comprises the step of applying pressure to the mass for an amount of time sufficient to form the composite article. The plurality of fibers maintains orientation of the plurality of lignocellulosic pieces in the mass while on the carrier. [0003] The plurality of fibers of the present disclosure results in composite articles having increased throughput via increased manufacturing speeds, e.g. press speeds.

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LIGNOCELLULOSIC COMPOSITE ARTICLE

SUMMARY OF THE DISCLOSURE AND ADVANTAGES

[0001]The present disclosure provides a composite article comprising a plurality of lignocellulosic pieces, a plurality of fibers, and a binder component. Each of fibers has a width to length aspect ratio of at least 1:100. The plurality of fibers maintains

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orientation of the plurality of lignocellulosic pieces during manufacture of the composite article.

[0002]The present disclosure further provides a method of forming the composite article. The method comprises the step of combining the binder component and the plurality of lignocellulosic pieces. The method further comprises the step of

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combining the plurality of fibers and the plurality of lignocellulosic pieces. The method also comprises the step of disposing the plurality of lignocellulosic pieces having the binder component and the plurality of fibers combined therewith on a carrier to form a mass. The method still further comprises the step of applying pressure to the mass for an amount of time sufficient to form the composite article.

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The plurality of fibers maintains orientation of the plurality of lignocellulosic pieces in the mass while on the carrier.

[0003]The plurality of fibers of the present disclosure results in composite articles having increased throughput via increased manufacturing speeds, e.g. press speeds.

BACKGROUND

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[0004]Lignocellulosic composite articles, such as oriented strand board (OSB), oriented strand lumber (OSL), particleboard (PB), scrimber, agrifiber board, chipboard, flakeboard, and fiberboard, e.g. medium density fiberboard (MDF), are generally produced by blending or spraying lignocellulosic pieces with a binder composition, e.g. a resin, while the lignocellulosic pieces are tumbled or agitated in a

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blender or similar apparatus. After blending sufficiently to form a binder- lignocellulosic mixture, the lignocellulosic pieces, which are now coated with the binder composition, are formed into a product, specifically a loose mat, which is compressed between heated platens/plates to set the binder composition and to bond the lignocellulosic pieces together in densified form, such as in a board, panel, or

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other shape. Conventional processes for compressing the loose mat are generally carried out at temperatures of from about 120°C to about 225°C, in the presence of

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varying amounts of steam, either purposefully injected into the loose mat or generated by liberation of entrained moisture from the lignocellulosic pieces in the loose mat. These processes also generally require that the moisture content of the lignocellulosic pieces be between about 2% and about 20% by weight, before blending the lignocellulosic pieces with the binder composition.

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[0005]The lignocellulosic pieces can be in the form of chips, shavings, strands, scrim, wafers, fibers, sawdust, bagasse, straw and wood wool. When the lignocellulosic pieces are relatively...