US20090075021A1 - Panel containing highly-cutinized bamboo flakes - Google Patents
Panel containing highly-cutinized bamboo flakes Download PDFInfo
- Publication number
- US20090075021A1 US20090075021A1 US12/259,780 US25978008A US2009075021A1 US 20090075021 A1 US20090075021 A1 US 20090075021A1 US 25978008 A US25978008 A US 25978008A US 2009075021 A1 US2009075021 A1 US 2009075021A1
- Authority
- US
- United States
- Prior art keywords
- bamboo
- strands
- oriented
- panel according
- inches
- 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.)
- Abandoned
Links
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
- B32B21/13—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board all layers being exclusively wood
-
- 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
- B27N3/002—Manufacture of substantially flat articles, e.g. boards, from particles or fibres characterised by the type of binder
-
- 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
- B27N3/04—Manufacture of substantially flat articles, e.g. boards, from particles or fibres from fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
- B32B21/02—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board the layer being formed of fibres, chips, or particles, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
- B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
- B32B3/14—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a face layer formed of separate pieces of material which are juxtaposed side-by-side
- B32B3/16—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a face layer formed of separate pieces of material which are juxtaposed side-by-side secured to a flexible backing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/03—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers with respect to the orientation of features
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
- B32B9/02—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising animal or vegetable substances, e.g. cork, bamboo, starch
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
- B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B9/042—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of wood
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/02—Composition of the impregnated, bonded or embedded layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/02—Composition of the impregnated, bonded or embedded layer
- B32B2260/026—Wood layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/04—Impregnation, embedding, or binder material
- B32B2260/046—Synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/54—Yield strength; Tensile strength
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/546—Flexural strength; Flexion stiffness
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/554—Wear resistance
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/732—Dimensional properties
- B32B2307/734—Dimensional stability
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2419/00—Buildings or parts thereof
- B32B2419/04—Tiles for floors or walls
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24058—Structurally defined web or sheet [e.g., overall dimension, etc.] including grain, strips, or filamentary elements in respective layers or components in angular relation
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24132—Structurally defined web or sheet [e.g., overall dimension, etc.] including grain, strips, or filamentary elements in different layers or components parallel
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
- Y10T428/249925—Fiber-containing wood product [e.g., hardboard, lumber, or wood board, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
- Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31971—Of carbohydrate
- Y10T428/31989—Of wood
Definitions
- bamboo is a wood material widely used throughout Asia as a building material because of its high strength, durability and excellent dimensional stability, as well as its ready supply and rapid replenishment—bamboo grows very rapidly, reaching full maturity within 2 to 6 years, while even the fastest growing wood tree species take as long as 15 to 30 years to grow to full maturity.
- bamboo also has a number of disadvantages. Since bamboo is hollow, it cannot be processed into solid lumber board or planks.
- bamboo can also not be processed by the conventional techniques used to make wood composite materials.
- bamboo been successfully processed by techniques used to make strand composite wood materials which are composite materials made from resin-coated strands given a preferred orientation and deposited in that orientation on an underpassing conveyor belt).
- composite bamboo structural panels may be made by hand-cutting bamboo strands from the outer part or surface of a bamboo culm, and then weaving (again, typically by hand) the strands into mats. These hand-cut, hand-woven bamboo mats are then stacked together along with several other similar mats, and the mats then pressed together under high temperature.
- the present invention relates to a wood panel comprising bamboo strands cut from the outer portion of the bamboo culm.
- FIG. 1 is a schematic representation of a panel according to an example embodiment of the present invention.
- lignocellulosic material is intended to mean a cellular structure having cell walls composed of cellulose and hemicellulose fibers bonded together by lignin polymer. Wood is a species of lignocellulosic material.
- wood composite material or “wood composite component” it is meant a composite material that comprises lignocellulosic material and one or more other additives, such as adhesives or waxes.
- wood composite materials include structural composite lumber (“SCL”), waferboard, particle board, chipboard, medium-density fiberboard, plywood, and boards that are a composite of strands and ply veneers.
- SCL structural composite lumber
- flakes”, “strands”, and “wafers” are considered equivalent to one another and are used interchangeably.
- a non-exclusive description of wood composite materials may be found in the Supplement Volume to the Kirk-Othmer Encyclopedia of Chemical Technology, pp 765-810, 6 th Edition, which is hereby incorporated by reference.
- SCL wood panel comprising bamboo strands cut from the outer portion of the bamboo culm.
- SCL products include laminated veneer lumber (“LVL”), parallel strand lumber (“PSL”), laminated strand lumber (“LSL”), oriented strand lumbers (“OSL”), and oriented strand board (“OSB”), which will be described in greater detail below.
- Forming a SCL product from strands cut from the outer portion of the bamboo culm results in a SCL wood panel having excellent strength durability characteristics because the outer portion of the bamboo culm is the strongest and most durable part of the bamboo culm.
- the isocyanates are selected from the diphenylmethane-p,p′-diisocyanate group of polymers, which have NCO— functional groups that can react with other organic groups to form polymer groups such as polyurea, —NCON—, and polyurethane, —NCOON—; a binder with about 50 wt % 4,4-diphenyl-methane diisocyanate (“MDI”) or in a mixture with other isocyanate oligomers; (“pMDI”) is preferred.
- MDI 4,4-diphenyl-methane diisocyanate
- pMDI 4,4-diphenyl-methane diisocyanate
- a suitable commercial pMDI product is Rubinate® 1840 available from Huntsman, Salt Lake City, Utah, and Mondur® 541 available from Bayer Corporation, North America, of Pittsburgh, Pa. Also suitable for use are phenol formaldehyde (“PF”), melamine formaldehyde, melamine urea formaldehyde (“MUF”) and the co-polymers thereof.
- PF phenol formaldehyde
- MUF melamine urea formaldehyde
- Suitable commercial MUF binders are the LS 2358 and LS 2250 products from the Dynea Corporation.
- MDI functions better than previously existing resin systems because the MDI is a smaller molecule than most polymer binder resins, and—of equal importance—because the MDI has a similar solubility with the wax coating found on the surface of the outer culm bamboo flakes.
- the bamboo material will now be described in greater detail, and, subsequently, methods of incorporating bamboo strands into a composite material will be discussed in detail.
- bamboo's basic components are cellulose fibers bonded together by lignin polymer, but bamboo differs from other wood materials in the organization and morphology of its constituent cells.
- most strength characteristics of bamboo tensile strength, flexural strength and rigidity
- the hardness of the bamboo culm itself is dependent on the density of bamboo fibers bundles and their manner of separation. The percentage of fibers does not consist either in the longitudinal direction of the bamboo culm or in a cross section of the culm.
- the density of fibers increases from the bottom of the culm to its top, while the density of fibers in the bamboo culm cross-section is highest closer to the outer surface and decreases going deeper into the core of the material.
- the strength and hardness of the outer portion of the bamboo culm is further increased by the presence of the silica-deposited, cutinized layer coated with wax, which covers the surface of the outer part of the culm.
- the bamboo on or near the outer surface of the culm has superior strength characteristics, but in most processes for making use of bamboo fibers, these improved strength properties are not exploited because the outer portion of the culm is stripped off.
- the cutinized layer is used and, thus, the high strength properties of the bamboo are maintained.
- the cellulose fibers in bamboo are stiffer and stronger than the fibers of most wood species, so that boards incorporating bamboo could have a much higher strength to weight ratio than boards made from other types of wood fibers.
- the bamboo culm strands are sorted depending on their location in the outer portion of the bamboo culm into strands that come from: (a) the outer third of the bamboo culm, (b) preferably the portion of the bamboo culm that is within 2 mm of the outer diameter of the bamboo culm.
- the bamboo strands are preferably cut into thicknesses of less than about 0.2 inch, such as less than 0.15 inches, such as in the range of about 0.01 inches to about 0.15 inches, and cut into widths of preferably greater than about 0.1 inches, such as more than about 0.15 inches, such as more than about 0.5 inches. This cutting may be done either manually or with mechanized clipping equipment.
- the bamboo strands should be cut along the longitudinal axis into strands preferably longer than about 2 inches, such as about 3 inches, such as about 5 inches. While not intending to be limited by theory, it is believed that the longer strip length will result in more closely aligned strands when the strands are oriented using a disk strand orienter, and, without being limited by theory, it is believed that more closely aligned strands will result in a final wood composite board product that has an improved modulus of elasticity along the longitudinal axis.
- the bamboo strands are dried (as described below) and coated with isocyanate polymeric resin (as described above).
- the binder concentration of the isocyante resin is in the range of about 2 wt % to about 12 wt %, based on the dry weight of the bamboo.
- a wax additive is commonly employed to enhance the resistance of the bamboo strands to moisture penetration.
- Preferred waxes are slack wax or an emulsion wax.
- the wax solids loading level is preferably in the range of about 0.1 wt % to about 3.0 wt % (based on the weight of the bamboo).
- the bamboo is formed into strand composite lumber panels, preferably OSB panels.
- the panels may be made entirely from bamboo strands, or, instead, the bamboo strands may be mixed with naturally occurring hard or soft woods, singularly or mixed, whether such wood is dry (having a moisture content of between 2 wt % and 12 wt %) or green (having a moisture content of between 30 wt % and 200 wt %).
- the raw wood starting materials either virgin or reclaimed, are cut into strands, wafers or flakes of desired size and shape, which are well known to one of ordinary skill in the art.
- the panels are made from a combination of both the bamboo strands and naturally occurring hard or soft woods
- the two separate sets of woods are separately dried and coated with polymer resin binder, and then after the separate coating stages, the coated hard/soft wood strands and coated bamboo strands are admixed together.
- the binder resin and the other various additives that are applied to the wood materials are referred to herein as a coating, even though the binder and additives may be in the form of small particles, such as atomized particles or solid particles, which do not form a continuous coating upon the wood material.
- the binder, wax and any other additives are applied to the wood materials by one or more spraying, blending or mixing techniques; a preferred technique is to spray the wax, resin and other additives upon the wood strands as the strands are tumbled in a drum blender.
- these coated strands are used to form a multi-layered mat 10 , preferably a three layered mat which is then pressed to form a composite wood component as generally shown in FIG. 1 .
- This layering may be done in the following fashion.
- the coated flakes 12 are spread on a conveyor belt to provide a first ply or layer 14 having flakes oriented substantially in line, or parallel, to the conveyor belt, then a second ply 16 is deposited on the first ply, with the flakes of the second ply oriented substantially perpendicular to the conveyor belt.
- all plies can have strands oriented in random directions.
- the multiple plies or layers can be deposited using generally known multi-pass techniques and strand orienter equipment.
- the first and third plies are surface layers, while the second ply is a core layer.
- the surface layers each have an exterior face.
- the above example may also be done in different relative directions, so that the first ply has flakes oriented substantially perpendicular to conveyor belt, then a second ply is deposited on the first ply with the flakes of the second ply oriented substantially parallel to the conveyor belt.
- the longitudinal edge of the board is formed parallel to the conveyor belt, so that flakes oriented substantially parallel to the conveyor belt will be oriented substantially arranged substantially parallel to the conveyor belt will end up being substantially parallel to the longitudinal edge of the final wood panel product.
- a third ply having flakes oriented substantially perpendicular with the conveyor belt, similar to the first ply, is deposited on the second ply.
- this configuration one or more layers are built up according to the aforementioned process to form the layers sufficient to form a composite wood component, and then a layer of bamboo strands is formed on top of these layers, with the bamboo strands substantially oriented in a direction parallel to the longitudinal edges to form a bamboo veneer layer.
- the binder resins used with the bamboo strands in this bamboo layer are as described above, and this bamboo layer and its accompanying wood layers are processed as described in the following paragraphs.
- isocyanate binder resins with the bamboo strands.
- conventional polymeric binder resins commonly used with wood composites may be used. These resins include urea-formaldehyde, polyvinyl acetate (“PVA”), phenol formaldehyde, melamine formaldehyde, melamine urea formaldehyde (“MUF”), the isocyantes mentioned and the co-polymers thereof.
- Isocyanates are the preferred binders, and preferably the isocyanates are selected from the diphenylmethane-p,p′-diisocyanate group of polymers, which have NCO— functional groups that can react with other organic groups to form polymer groups such as polyurea, —NCON—, and polyurethane, —NCOON—; a binder with about 50 wt % 4,4-diphenyl-methane diisocyanate (“MDI”) or in a mixture with other isocyanate oligomers (“pMDI”) is preferred.
- MDI 4,4-diphenyl-methane diisocyanate
- pMDI isocyanate oligomers
- MDI is used in the present invention as the polymeric resin; in addition to the 4,4-diphenyl-methane diisocyanate (“MDI”) mentioned above other isocyanate oligomers (“pMDI”) may be used.
- MDI 4,4-diphenyl-methane diisocyanate
- pMDI isocyanate oligomers
- a suitable commercial pMDI product is Rubinate® 1840 available from Huntsman, Salt Lake City, Utah, and Mondur® 541 available from Bayer Corporation, North America, of Pittsburgh, Pa.
- Other polymeric resins may be used as well in a resin blend.
- the MDI loading levels may be slightly reduced by inclusion of a small amount of phenol formaldehyde.
- the binder concentration in the non-bamboo layers is preferably in the range of about 0.2 wt % to about 2 wt %.
- a wax additive is commonly employed to enhance the resistance of the OSB panels to moisture penetration.
- Preferred waxes are slack wax or an emulsion wax.
- the wax solids loading level is preferably in the range of about 0.1 wt % to about 3.0 wt % (based on the weight of the wood).
- the multi-layered mats are formed according to the process discussed above, they are compressed under a hot press machine that fuses and binds together the wood materials, binder, and other additives to form consolidated OSB panels of various thickness and sizes.
- the high temperature also acts to cure the binder material.
- the panels of the invention are pressed for 2-15 minutes at a temperature of about 175° C. to about 240° C.
- the resulting composite panels will have a density in the range of about 35 lbs/ft 3 to about 48 lbs/ft 3 (as measured by ASTM standard D1037-98).
- the density ranges from 40 lbs/ft 3 to 48 lbs/ft 3 for southern pine and 35 lbs lbs/ft 3 to 42 lbs/ft 3 for Aspen.
- the thickness of the OSB panels will be from about 0.6 cm (about 1 ⁇ 4′′) to about 5 cm (about 2′′), such as about 1.25 cm to about 6 cm, such as about 2.8 cm to about 3.8 cm.
Abstract
A wood composite panel includes bamboo strands cut from the outer cutinized portion of a bamboo culm and bound together with an isocyanate binder resin.
Description
- This application is a continuation of pending U.S. patent application Ser. No. 11/216,655, which was filed on Aug. 31, 2005 and is entitled “PANEL CONTAINING HIGHLY-CUTINIZED BAMBOO FLAKES.” The disclosure of application Ser. No. 11/216,655 is hereby incorporated by reference in its entirety for all purposes.
- Bamboo is a wood material widely used throughout Asia as a building material because of its high strength, durability and excellent dimensional stability, as well as its ready supply and rapid replenishment—bamboo grows very rapidly, reaching full maturity within 2 to 6 years, while even the fastest growing wood tree species take as long as 15 to 30 years to grow to full maturity.
- However, in addition to these advantages, bamboo also has a number of disadvantages. Since bamboo is hollow, it cannot be processed into solid lumber board or planks.
- And, not only is it impossible to make solid lumber from, but bamboo can also not be processed by the conventional techniques used to make wood composite materials. For example, it is difficult to make plywood from bamboo because the bamboo culms are too thin to cut plywood veneers from. Nor has bamboo been successfully processed by techniques used to make strand composite wood materials (which are composite materials made from resin-coated strands given a preferred orientation and deposited in that orientation on an underpassing conveyor belt).
- Despite these disadvantages, because of bamboo's ready supply and excellent performance characteristics, manufacturers have developed techniques to make wood composite materials out of bamboo. For example, composite bamboo structural panels may be made by hand-cutting bamboo strands from the outer part or surface of a bamboo culm, and then weaving (again, typically by hand) the strands into mats. These hand-cut, hand-woven bamboo mats are then stacked together along with several other similar mats, and the mats then pressed together under high temperature.
- The problem with this method of manufacture of the bamboo boards is that it is time consuming; the steps of cutting the bamboo strips and then weaving the bamboo strips into the form of a mat take a significant amount of time. And, not only are these processes time consuming, but they can lead to significant defects in the final board product. For example, internal gaps created by the layering of several of the mats on top of another can result in the production of holes or other defects in the board that can lead to failure. Additionally, bonding two woven bamboo mats together involves bonding together two mating surfaces, which is an additional source for defects. Yet another disadvantage of the aforementioned processes is that because they are composed of large numbers of bamboo layers, they are require very high doses of resin per layer, which adds greatly to the price of the product during periods of high petroleum prices.
- Given the foregoing, there is a need in the art for structural bamboo panels that are either partly or completely composed of bamboo, have fewer defects, do not require a lengthy manufacturing process, and consume a smaller amount of petroleum-based products.
- The present invention relates to a wood panel comprising bamboo strands cut from the outer portion of the bamboo culm.
-
FIG. 1 is a schematic representation of a panel according to an example embodiment of the present invention. - All parts, percentages and ratios used herein are expressed by weight unless otherwise specified. All documents cited herein are incorporated by reference.
- As used herein, “lignocellulosic material” is intended to mean a cellular structure having cell walls composed of cellulose and hemicellulose fibers bonded together by lignin polymer. Wood is a species of lignocellulosic material.
- By “wood composite material” or “wood composite component” it is meant a composite material that comprises lignocellulosic material and one or more other additives, such as adhesives or waxes. Non-limiting examples of wood composite materials include structural composite lumber (“SCL”), waferboard, particle board, chipboard, medium-density fiberboard, plywood, and boards that are a composite of strands and ply veneers. As used herein, “flakes”, “strands”, and “wafers” are considered equivalent to one another and are used interchangeably. A non-exclusive description of wood composite materials may be found in the Supplement Volume to the Kirk-Othmer Encyclopedia of Chemical Technology, pp 765-810, 6th Edition, which is hereby incorporated by reference.
- The following describes preferred embodiments of the present invention, which provide a SCL wood panel comprising bamboo strands cut from the outer portion of the bamboo culm. SCL products include laminated veneer lumber (“LVL”), parallel strand lumber (“PSL”), laminated strand lumber (“LSL”), oriented strand lumbers (“OSL”), and oriented strand board (“OSB”), which will be described in greater detail below.
- Forming a SCL product from strands cut from the outer portion of the bamboo culm results in a SCL wood panel having excellent strength durability characteristics because the outer portion of the bamboo culm is the strongest and most durable part of the bamboo culm.
- Previously, attempts to use flakes from the outer portion of the bamboo culm have been frustrated because conventional wood composite resins (like phenol formaldehyde) could not penetrate into the flakes taken from the outer layer (because of the waxy and highly-cutinized surface coating of the flakes) and consequently failed to form strong bonds between adjacent flakes.
- This problem has been solved in the present invention by the use of one or more isocyanate binder resins, preferably the isocyanates are selected from the diphenylmethane-p,p′-diisocyanate group of polymers, which have NCO— functional groups that can react with other organic groups to form polymer groups such as polyurea, —NCON—, and polyurethane, —NCOON—; a binder with about 50 wt % 4,4-diphenyl-methane diisocyanate (“MDI”) or in a mixture with other isocyanate oligomers; (“pMDI”) is preferred. A suitable commercial pMDI product is Rubinate® 1840 available from Huntsman, Salt Lake City, Utah, and Mondur® 541 available from Bayer Corporation, North America, of Pittsburgh, Pa. Also suitable for use are phenol formaldehyde (“PF”), melamine formaldehyde, melamine urea formaldehyde (“MUF”) and the co-polymers thereof. Suitable commercial MUF binders are the LS 2358 and LS 2250 products from the Dynea Corporation.
- Without wishing to be limited by theory, it is believed that MDI functions better than previously existing resin systems because the MDI is a smaller molecule than most polymer binder resins, and—of equal importance—because the MDI has a similar solubility with the wax coating found on the surface of the outer culm bamboo flakes.
- The bamboo material will now be described in greater detail, and, subsequently, methods of incorporating bamboo strands into a composite material will be discussed in detail.
- Like other wood materials, bamboo's basic components are cellulose fibers bonded together by lignin polymer, but bamboo differs from other wood materials in the organization and morphology of its constituent cells. Generally, most strength characteristics of bamboo (tensile strength, flexural strength and rigidity) are greatest in the longitudinal direction of the bamboo and the bamboo fibers. This is due to the relatively small micro-fibrillar angle of the cellulose fibers in the longitudinal direction. The hardness of the bamboo culm itself is dependent on the density of bamboo fibers bundles and their manner of separation. The percentage of fibers does not consist either in the longitudinal direction of the bamboo culm or in a cross section of the culm. In the longitudinal direction, the density of fibers increases from the bottom of the culm to its top, while the density of fibers in the bamboo culm cross-section is highest closer to the outer surface and decreases going deeper into the core of the material. Moreover, the strength and hardness of the outer portion of the bamboo culm is further increased by the presence of the silica-deposited, cutinized layer coated with wax, which covers the surface of the outer part of the culm. Thus, the bamboo on or near the outer surface of the culm has superior strength characteristics, but in most processes for making use of bamboo fibers, these improved strength properties are not exploited because the outer portion of the culm is stripped off. Unlike previous techniques for using bamboo wood in which the cutinized layer is stripped off and, thus, the strongest part of the culm discarded, in the present invention the cutinized layer is used and, thus, the high strength properties of the bamboo are maintained.
- Thus, when properly utilized the cellulose fibers in bamboo are stiffer and stronger than the fibers of most wood species, so that boards incorporating bamboo could have a much higher strength to weight ratio than boards made from other types of wood fibers.
- In the present invention the bamboo culm strands are sorted depending on their location in the outer portion of the bamboo culm into strands that come from: (a) the outer third of the bamboo culm, (b) preferably the portion of the bamboo culm that is within 2 mm of the outer diameter of the bamboo culm. For improved compatibility and adhesion with the conventional wood strands, the bamboo strands are preferably cut into thicknesses of less than about 0.2 inch, such as less than 0.15 inches, such as in the range of about 0.01 inches to about 0.15 inches, and cut into widths of preferably greater than about 0.1 inches, such as more than about 0.15 inches, such as more than about 0.5 inches. This cutting may be done either manually or with mechanized clipping equipment. For purposes of improved strength the bamboo strands should be cut along the longitudinal axis into strands preferably longer than about 2 inches, such as about 3 inches, such as about 5 inches. While not intending to be limited by theory, it is believed that the longer strip length will result in more closely aligned strands when the strands are oriented using a disk strand orienter, and, without being limited by theory, it is believed that more closely aligned strands will result in a final wood composite board product that has an improved modulus of elasticity along the longitudinal axis.
- After being cut, the bamboo strands are dried (as described below) and coated with isocyanate polymeric resin (as described above). The binder concentration of the isocyante resin is in the range of about 2 wt % to about 12 wt %, based on the dry weight of the bamboo. A wax additive is commonly employed to enhance the resistance of the bamboo strands to moisture penetration. Preferred waxes are slack wax or an emulsion wax. The wax solids loading level is preferably in the range of about 0.1 wt % to about 3.0 wt % (based on the weight of the bamboo).
- As used in the present invention the bamboo is formed into strand composite lumber panels, preferably OSB panels. The panels may be made entirely from bamboo strands, or, instead, the bamboo strands may be mixed with naturally occurring hard or soft woods, singularly or mixed, whether such wood is dry (having a moisture content of between 2 wt % and 12 wt %) or green (having a moisture content of between 30 wt % and 200 wt %). Typically, the raw wood starting materials, either virgin or reclaimed, are cut into strands, wafers or flakes of desired size and shape, which are well known to one of ordinary skill in the art. When the panels are made from a combination of both the bamboo strands and naturally occurring hard or soft woods, the two separate sets of woods are separately dried and coated with polymer resin binder, and then after the separate coating stages, the coated hard/soft wood strands and coated bamboo strands are admixed together.
- After the strands are cut they are dried in an oven and then coated with a special formulation of one or more polymeric thermosetting binder resins, waxes and other additives. The binder resin and the other various additives that are applied to the wood materials are referred to herein as a coating, even though the binder and additives may be in the form of small particles, such as atomized particles or solid particles, which do not form a continuous coating upon the wood material. Conventionally, the binder, wax and any other additives are applied to the wood materials by one or more spraying, blending or mixing techniques; a preferred technique is to spray the wax, resin and other additives upon the wood strands as the strands are tumbled in a drum blender.
- After being coated and treated with the desired coating and treatment chemicals, these coated strands are used to form a
multi-layered mat 10, preferably a three layered mat which is then pressed to form a composite wood component as generally shown inFIG. 1 . This layering may be done in the following fashion. The coatedflakes 12 are spread on a conveyor belt to provide a first ply orlayer 14 having flakes oriented substantially in line, or parallel, to the conveyor belt, then asecond ply 16 is deposited on the first ply, with the flakes of the second ply oriented substantially perpendicular to the conveyor belt. Finally, athird ply 18 having flakes oriented substantially in line with the conveyor belt, similar to thefirst ply 14, is deposited on thesecond ply 16 such that plies built-up in this manner have flakes oriented generally perpendicular to a neighboring ply. Alternatively, but less preferably, all plies can have strands oriented in random directions. The multiple plies or layers can be deposited using generally known multi-pass techniques and strand orienter equipment. In the case of a three ply or three layered mat, the first and third plies are surface layers, while the second ply is a core layer. The surface layers each have an exterior face. - The above example may also be done in different relative directions, so that the first ply has flakes oriented substantially perpendicular to conveyor belt, then a second ply is deposited on the first ply with the flakes of the second ply oriented substantially parallel to the conveyor belt. In the present invention, the longitudinal edge of the board is formed parallel to the conveyor belt, so that flakes oriented substantially parallel to the conveyor belt will be oriented substantially arranged substantially parallel to the conveyor belt will end up being substantially parallel to the longitudinal edge of the final wood panel product. Finally, a third ply having flakes oriented substantially perpendicular with the conveyor belt, similar to the first ply, is deposited on the second ply.
- In the present invention there is another possible panel configuration. In this configuration one or more layers are built up according to the aforementioned process to form the layers sufficient to form a composite wood component, and then a layer of bamboo strands is formed on top of these layers, with the bamboo strands substantially oriented in a direction parallel to the longitudinal edges to form a bamboo veneer layer. The binder resins used with the bamboo strands in this bamboo layer are as described above, and this bamboo layer and its accompanying wood layers are processed as described in the following paragraphs.
- As discussed above, an important part of the present invention is the use of isocyanate binder resins with the bamboo strands. However, with conventional pine, aspen or the like wood strands, conventional polymeric binder resins commonly used with wood composites may be used. These resins include urea-formaldehyde, polyvinyl acetate (“PVA”), phenol formaldehyde, melamine formaldehyde, melamine urea formaldehyde (“MUF”), the isocyantes mentioned and the co-polymers thereof.
- Isocyanates are the preferred binders, and preferably the isocyanates are selected from the diphenylmethane-p,p′-diisocyanate group of polymers, which have NCO— functional groups that can react with other organic groups to form polymer groups such as polyurea, —NCON—, and polyurethane, —NCOON—; a binder with about 50 wt % 4,4-diphenyl-methane diisocyanate (“MDI”) or in a mixture with other isocyanate oligomers (“pMDI”) is preferred.
- As mentioned above, MDI is used in the present invention as the polymeric resin; in addition to the 4,4-diphenyl-methane diisocyanate (“MDI”) mentioned above other isocyanate oligomers (“pMDI”) may be used. A suitable commercial pMDI product is Rubinate® 1840 available from Huntsman, Salt Lake City, Utah, and Mondur® 541 available from Bayer Corporation, North America, of Pittsburgh, Pa. Other polymeric resins may be used as well in a resin blend. For example, the MDI loading levels may be slightly reduced by inclusion of a small amount of phenol formaldehyde.
- The binder concentration in the non-bamboo layers is preferably in the range of about 0.2 wt % to about 2 wt %. A wax additive is commonly employed to enhance the resistance of the OSB panels to moisture penetration. Preferred waxes are slack wax or an emulsion wax. The wax solids loading level is preferably in the range of about 0.1 wt % to about 3.0 wt % (based on the weight of the wood).
- After the multi-layered mats are formed according to the process discussed above, they are compressed under a hot press machine that fuses and binds together the wood materials, binder, and other additives to form consolidated OSB panels of various thickness and sizes. The high temperature also acts to cure the binder material. Preferably, the panels of the invention are pressed for 2-15 minutes at a temperature of about 175° C. to about 240° C. The resulting composite panels will have a density in the range of about 35 lbs/ft3 to about 48 lbs/ft3 (as measured by ASTM standard D1037-98). The density ranges from 40 lbs/ft3 to 48 lbs/ft3 for southern pine and 35 lbs lbs/ft3 to 42 lbs/ft3 for Aspen. The thickness of the OSB panels will be from about 0.6 cm (about ¼″) to about 5 cm (about 2″), such as about 1.25 cm to about 6 cm, such as about 2.8 cm to about 3.8 cm.
- It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims.
Claims (17)
1. A panel, comprising:
bamboo strands cut from only an outer cutinized layer of a bamboo culm along its longitudinal axis; and
an isocyanate binder resin, wherein the isocyanate binder resin binds the bamboo strands together.
2. The panel according to claim 1 , wherein the bamboo strands are cut from the outer half of the bamboo culm.
3. The panel according to claim 1 , wherein the bamboo strands are cut from the outer third of the bamboo culm.
4. The panel according to claim 1 , wherein the bamboo strands each have a thickness of no more than about 0.2 inches.
5. The panel according to claim 4 , wherein the bamboo strands each have a thickness of about 0.01 inches to about 0.15 inches.
6. The panel according to claim 1 , wherein the bamboo strands each have a width greater than about 0.1 inches.
7. The panel according to claim 1 , wherein the bamboo strands each have a length of at least about 2 inches.
8. The panel according to claim 1 , wherein the isocyanate binder resin is MDI.
9. The panel according to claim 1 , wherein the isocyanate binder resin is about 2 wt % to about 12 wt % of the dry weight of the bamboo strands.
10. A panel having parallel first and second longitudinal edges, the panel comprising:
a composite wood component defining a mating surface;
a bamboo layer defining a mating surface adjacent the composite wood component mating surface, the bamboo layer comprising bamboo strands substantially oriented in a direction parallel to the longitudinal edges, wherein the bamboo strands are cut from an outer cutinized portion of the bamboo culm and are bonded to each other by an isocyanate binder resin.
11. The panel according to claim 10 , wherein the isocyanate binder resin is MDI.
12. The panel according to claim 11 , wherein the composite wood component comprises strands selected from aspen wood and pine wood.
13. A panel, comprising:
a layer of oriented bamboo strands cut from an outer portion of a bamboo culm, wherein the outer portion is the portion of the bamboo culm that is within about two millimeters of its outer diameter;
an isocyanate binder resin coating the oriented bamboo strands, wherein the isocyanate binder comprises about 2 wt % to about 12 wt % of the dry weight of the oriented bamboo strands,
wherein the oriented bamboo strands have lengths of at least about three inches long, widths of at least about 0.1 inches, and thicknesses of no more than about 0.2 inch.
14. The panel according to claim 13 , wherein the panel has first and second longitudinal edges and wherein the bamboo strands are oriented substantially parallel to the longitudinal edges.
15. The panel according to claim 14 , further comprising a second layer of oriented bamboo strands cut from the outer portion of the bamboo culm, and an isocyanate binder resin coating the oriented bamboo strands, wherein the isocyanate binder comprises about 2 wt % to about 12 wt % of the dry weight of the oriented bamboo strands, wherein the oriented bamboo strands generally all have lengths of at least about three inches long, widths of at least about 0.1 inches, and thicknesses no more than about 0.2 inch, and wherein the bamboo strands of the second layer are substantially oriented perpendicularly to the longitudinal edges.
16. The panel according to claim 14 , further comprising a layer of oriented strands, wherein the oriented strands comprises strands of wood other than bamboo.
17. The panel according to claim 13 , wherein the layer of oriented bamboo strands further includes strands of wood other than bamboo.
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/259,780 US20090075021A1 (en) | 2005-08-31 | 2008-10-28 | Panel containing highly-cutinized bamboo flakes |
US12/405,110 US20090263617A1 (en) | 2005-08-31 | 2009-03-16 | Panel containing bamboo |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/216,655 US7459206B2 (en) | 2005-08-31 | 2005-08-31 | Panel containing highly-cutinized bamboo flakes |
US12/259,780 US20090075021A1 (en) | 2005-08-31 | 2008-10-28 | Panel containing highly-cutinized bamboo flakes |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/216,655 Continuation US7459206B2 (en) | 2005-08-31 | 2005-08-31 | Panel containing highly-cutinized bamboo flakes |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US12/405,110 Continuation-In-Part US20090263617A1 (en) | 2005-08-31 | 2009-03-16 | Panel containing bamboo |
Publications (1)
Publication Number | Publication Date |
---|---|
US20090075021A1 true US20090075021A1 (en) | 2009-03-19 |
Family
ID=37804570
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/216,655 Expired - Fee Related US7459206B2 (en) | 2005-08-31 | 2005-08-31 | Panel containing highly-cutinized bamboo flakes |
US12/259,780 Abandoned US20090075021A1 (en) | 2005-08-31 | 2008-10-28 | Panel containing highly-cutinized bamboo flakes |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/216,655 Expired - Fee Related US7459206B2 (en) | 2005-08-31 | 2005-08-31 | Panel containing highly-cutinized bamboo flakes |
Country Status (7)
Country | Link |
---|---|
US (2) | US7459206B2 (en) |
CN (1) | CN101277818A (en) |
AR (1) | AR056485A1 (en) |
CA (1) | CA2621012C (en) |
PE (1) | PE20070440A1 (en) |
TW (1) | TW200728570A (en) |
WO (1) | WO2007027405A2 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20100113193A1 (en) * | 2008-11-05 | 2010-05-06 | Pinnacle Sports Equipment Co., Inc. | Bamboo bat having fiber-fused core and method of manufacturing the same |
Families Citing this family (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20070077445A1 (en) * | 2005-09-30 | 2007-04-05 | Lawson Eric N | Panel containing bamboo and fungicide |
US7459206B2 (en) * | 2005-08-31 | 2008-12-02 | Huber Engineered Woods Llc | Panel containing highly-cutinized bamboo flakes |
US8161697B1 (en) * | 2007-06-27 | 2012-04-24 | Bamcore LLC | Studless load bearing panel wall system |
US8309221B2 (en) | 2007-10-01 | 2012-11-13 | Jay Plaehn | Reinforced foam panel |
CN105816990A (en) * | 2015-01-06 | 2016-08-03 | 张仲甫 | Treadmill buffer plate structure |
SE543403C2 (en) * | 2019-05-02 | 2021-01-05 | Stora Enso Oyj | Method for manufacturing laminated veneer lumer product |
Citations (48)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US576338A (en) * | 1897-02-02 | Metal-punching machine | ||
US3684632A (en) * | 1971-02-04 | 1972-08-15 | Rafael De Jesus Pedraza | Laminated pallet and method of making same |
US3859162A (en) * | 1973-05-11 | 1975-01-07 | Minnesota Mining & Mfg | Pre-preg materials, chemically integral composite foam structures prepared therefrom, and methods of preparation |
US4451310A (en) * | 1981-04-14 | 1984-05-29 | Nobel-Bozel | Preparation of lightweight, insulating and semirigid or rigid elements |
US4810551A (en) * | 1985-12-16 | 1989-03-07 | Chu Alan C | Bamboo board |
US4833182A (en) * | 1986-09-29 | 1989-05-23 | Jim Walter Research Corp. | Isocyanate-polyester polyol binder for manufacture of cellulosic composites |
US5128407A (en) * | 1991-07-25 | 1992-07-07 | Miles Inc. | Urea extended polyisocyanates |
US5441787A (en) * | 1994-01-28 | 1995-08-15 | The Forestry And Forest Products Research Institute | Composite wood product and method for manufacturing same |
US5505238A (en) * | 1994-02-14 | 1996-04-09 | The Forestry And Forest Products Research Institute | Apparatus for composite wood product manufacturing |
US5543187A (en) * | 1994-10-11 | 1996-08-06 | Errico; Joseph P. | Amorphous metal - ceramic composite material |
US5543197A (en) * | 1994-02-18 | 1996-08-06 | Plaehn; Jay | Parallel randomly stacked, stranded, laminated bamboo boards and beams |
US5636577A (en) * | 1995-09-14 | 1997-06-10 | Gow; Robert H. | Bamboo pallet |
US5651744A (en) * | 1996-06-25 | 1997-07-29 | Stx, Inc. | Lacrosse stick having offset handle |
US5675951A (en) * | 1995-10-12 | 1997-10-14 | Gow; Robert H. | Bamboo workpiece, molding and trim and method for making |
US5759463A (en) * | 1997-03-10 | 1998-06-02 | Chang; Kou-I | Method for manufacturing a sandwiched sheet |
US5786063A (en) * | 1996-08-22 | 1998-07-28 | The Forestry And Forest Products Research Institute | Wood composite layered material |
US5869576A (en) * | 1996-12-23 | 1999-02-09 | Shell Oil Company | Graft copolymerized compositions |
US5882745A (en) * | 1997-03-28 | 1999-03-16 | The Hongkong Univiersity Of Science & Technology | Bamboo fiber reinforced polypropylene composites |
US5972467A (en) * | 1998-07-23 | 1999-10-26 | Washo; Kenji | Pressure forming process for pressure-formed bamboo products |
US6047931A (en) * | 1999-02-15 | 2000-04-11 | Bamboo Fencer, Inc. | Bamboo support base assembled from helical structure |
US6183849B1 (en) * | 1999-09-17 | 2001-02-06 | Exxon Research And Engineering Company | Method for manufacturing composite board using high oil content wax and the composite board made using high oil content wax |
US6197414B1 (en) * | 1997-12-25 | 2001-03-06 | Matsushita Electric Works, Ltd. | Fiberboard and manufacturing method thereof |
US6224800B1 (en) * | 1998-12-17 | 2001-05-01 | Bayer Corporation | Extended polymethylene poly(phenylisocyanate) resin binders for the production of wood composite products |
US6224698B1 (en) * | 1994-06-28 | 2001-05-01 | Nichiha Corporation | Method of manufacturing an inorganic board |
US6281148B1 (en) * | 1998-01-27 | 2001-08-28 | University Of Maine | Resin starved impregnated panels, wood composites utilizing said panels and methods of making the same |
US6383652B1 (en) * | 1996-01-30 | 2002-05-07 | Tt Technologies, Inc. | Weatherable building products |
US6420034B1 (en) * | 1998-10-13 | 2002-07-16 | Mitsui Chemicals, Inc. | Binder composition and process for manufacturing board by using the binder composition |
US6451153B1 (en) * | 1994-10-31 | 2002-09-17 | Tower Technologies (Proprietary) Limited | Method of preparing a lignocellulosic material for the manufacture of a finished product |
US6511757B1 (en) * | 1996-10-29 | 2003-01-28 | Crane Plastics Company Llc | Compression molding of synthetic wood material |
US6576331B1 (en) * | 1996-08-14 | 2003-06-10 | Dale Bradley Ryan | Load-carrying structures comprising bamboo fibers and polymers |
US20030150522A1 (en) * | 2002-02-13 | 2003-08-14 | Toshiyuki Suzuki | Process for producing woody composite material |
US6620459B2 (en) * | 2001-02-13 | 2003-09-16 | Houston Advanced Research Center | Resin-impregnated substrate, method of manufacture and system therefor |
US6641885B2 (en) * | 2001-11-30 | 2003-11-04 | Wei Rong Dong Guan Bamboo & Wood Products | Complex laminated bamboo board |
US6648363B2 (en) * | 2001-12-05 | 2003-11-18 | Shale Gordon | Composite sports board such as a skateboard deck |
US6689298B2 (en) * | 2000-01-31 | 2004-02-10 | Japan Blower Ind. Co., Ltd. | Bamboo fiber board method |
US6713168B2 (en) * | 2001-07-12 | 2004-03-30 | J.M. Huber Corporation | Fire retardant wood composite materials |
US20040062915A1 (en) * | 2002-10-01 | 2004-04-01 | Pabedinskas Arunas Antanas | Reinforced composite structural members |
US6755757B2 (en) * | 1998-03-18 | 2004-06-29 | Ce Composites Baseball Inc. | Composite over-wrapped lightweight core and method |
US6772569B2 (en) * | 2002-02-06 | 2004-08-10 | John Landus Bennett | Tongue and groove panel |
US6841231B1 (en) * | 2000-08-10 | 2005-01-11 | Masonite Corporation | Fibrous composite article and method of making the same |
US20050075201A1 (en) * | 2003-10-03 | 2005-04-07 | Cullen Stephen M. | Composite bamboo sporting implement |
US6881771B2 (en) * | 2001-08-22 | 2005-04-19 | Bayer Aktiengesellschaft | Process for producing press molded materials |
US20050153150A1 (en) * | 2003-08-27 | 2005-07-14 | Rob Wellwood | Container flooring material and method of manufacture |
US20050161852A1 (en) * | 2004-01-27 | 2005-07-28 | Decker Emil G. | Bamboo chip treatment and products |
US20050202226A1 (en) * | 2002-04-03 | 2005-09-15 | Alfonso Branca | Wooden element and method for its manufacture |
US20070049152A1 (en) * | 2005-08-31 | 2007-03-01 | Ou Nian-Hua | Panel containing bamboo |
US20070048541A1 (en) * | 2005-08-31 | 2007-03-01 | Ou Nian-Hua | Wood panel containing inner culm flakes |
US7459206B2 (en) * | 2005-08-31 | 2008-12-02 | Huber Engineered Woods Llc | Panel containing highly-cutinized bamboo flakes |
Family Cites Families (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB8916542D0 (en) | 1989-07-20 | 1989-09-06 | Chu Wa | Bamboo core board |
JP2502903B2 (en) | 1992-12-22 | 1996-05-29 | 芙蓉工業株式会社 | Bamboo particle board manufacturing method |
US5789463A (en) * | 1994-06-07 | 1998-08-04 | Tomey Technology Corporation | Ocular lens material and process for producing the same |
AU7704694A (en) | 1994-09-29 | 1996-04-19 | Shui Fong Chan | Structural board |
JPH09279822A (en) | 1996-04-18 | 1997-10-28 | Eijiro Ota | Bamboo-made flooring material |
JPH10113914A (en) | 1996-10-14 | 1998-05-06 | Ig Tech Res Inc | Bamboo board |
JP3738792B2 (en) | 1996-10-15 | 2006-01-25 | 株式会社アイジー技術研究所 | Bamboo composite board |
JP3433133B2 (en) | 1999-04-01 | 2003-08-04 | 株式会社三葉 | Bamboo laminated flooring manufacturing method, bamboo laminated flooring manufactured by the manufacturing method, and floor structure using the bamboo laminated flooring |
JP2002036211A (en) | 2000-07-25 | 2002-02-05 | Ishida Engineering Kk | Panel board using bamboo material as core |
DE20018817U1 (en) | 2000-11-03 | 2001-01-11 | Gpm Ges Fuer Produkt Man Mbh | Plate element |
NL1019971C2 (en) | 2002-01-11 | 2003-07-15 | Mvp Internat B V | Method for manufacturing bamboo veneer and manufacturing bamboo veneer by applying such a method. |
-
2005
- 2005-08-31 US US11/216,655 patent/US7459206B2/en not_active Expired - Fee Related
-
2006
- 2006-08-11 CA CA 2621012 patent/CA2621012C/en not_active Expired - Fee Related
- 2006-08-11 CN CNA2006800364497A patent/CN101277818A/en active Pending
- 2006-08-11 WO PCT/US2006/031381 patent/WO2007027405A2/en active Application Filing
- 2006-08-29 PE PE2006001046A patent/PE20070440A1/en not_active Application Discontinuation
- 2006-08-31 AR ARP060103824 patent/AR056485A1/en unknown
- 2006-08-31 TW TW095132167A patent/TW200728570A/en unknown
-
2008
- 2008-10-28 US US12/259,780 patent/US20090075021A1/en not_active Abandoned
Patent Citations (51)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US576338A (en) * | 1897-02-02 | Metal-punching machine | ||
US3684632A (en) * | 1971-02-04 | 1972-08-15 | Rafael De Jesus Pedraza | Laminated pallet and method of making same |
US3859162A (en) * | 1973-05-11 | 1975-01-07 | Minnesota Mining & Mfg | Pre-preg materials, chemically integral composite foam structures prepared therefrom, and methods of preparation |
US4451310A (en) * | 1981-04-14 | 1984-05-29 | Nobel-Bozel | Preparation of lightweight, insulating and semirigid or rigid elements |
US4810551A (en) * | 1985-12-16 | 1989-03-07 | Chu Alan C | Bamboo board |
US4833182A (en) * | 1986-09-29 | 1989-05-23 | Jim Walter Research Corp. | Isocyanate-polyester polyol binder for manufacture of cellulosic composites |
US5128407A (en) * | 1991-07-25 | 1992-07-07 | Miles Inc. | Urea extended polyisocyanates |
US5441787A (en) * | 1994-01-28 | 1995-08-15 | The Forestry And Forest Products Research Institute | Composite wood product and method for manufacturing same |
US5505238A (en) * | 1994-02-14 | 1996-04-09 | The Forestry And Forest Products Research Institute | Apparatus for composite wood product manufacturing |
US5543197A (en) * | 1994-02-18 | 1996-08-06 | Plaehn; Jay | Parallel randomly stacked, stranded, laminated bamboo boards and beams |
US6224698B1 (en) * | 1994-06-28 | 2001-05-01 | Nichiha Corporation | Method of manufacturing an inorganic board |
US5543187A (en) * | 1994-10-11 | 1996-08-06 | Errico; Joseph P. | Amorphous metal - ceramic composite material |
US6451153B1 (en) * | 1994-10-31 | 2002-09-17 | Tower Technologies (Proprietary) Limited | Method of preparing a lignocellulosic material for the manufacture of a finished product |
US5636577A (en) * | 1995-09-14 | 1997-06-10 | Gow; Robert H. | Bamboo pallet |
US5675951A (en) * | 1995-10-12 | 1997-10-14 | Gow; Robert H. | Bamboo workpiece, molding and trim and method for making |
US6383652B1 (en) * | 1996-01-30 | 2002-05-07 | Tt Technologies, Inc. | Weatherable building products |
US5651744A (en) * | 1996-06-25 | 1997-07-29 | Stx, Inc. | Lacrosse stick having offset handle |
US6576331B1 (en) * | 1996-08-14 | 2003-06-10 | Dale Bradley Ryan | Load-carrying structures comprising bamboo fibers and polymers |
US5814170A (en) * | 1996-08-22 | 1998-09-29 | The Forestry And Forest Research Institute | Manufacturing method for a wood composite layered material |
US5786063A (en) * | 1996-08-22 | 1998-07-28 | The Forestry And Forest Products Research Institute | Wood composite layered material |
US6511757B1 (en) * | 1996-10-29 | 2003-01-28 | Crane Plastics Company Llc | Compression molding of synthetic wood material |
US5869576A (en) * | 1996-12-23 | 1999-02-09 | Shell Oil Company | Graft copolymerized compositions |
US5759463A (en) * | 1997-03-10 | 1998-06-02 | Chang; Kou-I | Method for manufacturing a sandwiched sheet |
US5882745A (en) * | 1997-03-28 | 1999-03-16 | The Hongkong Univiersity Of Science & Technology | Bamboo fiber reinforced polypropylene composites |
US6197414B1 (en) * | 1997-12-25 | 2001-03-06 | Matsushita Electric Works, Ltd. | Fiberboard and manufacturing method thereof |
US6281148B1 (en) * | 1998-01-27 | 2001-08-28 | University Of Maine | Resin starved impregnated panels, wood composites utilizing said panels and methods of making the same |
US6755757B2 (en) * | 1998-03-18 | 2004-06-29 | Ce Composites Baseball Inc. | Composite over-wrapped lightweight core and method |
US5972467A (en) * | 1998-07-23 | 1999-10-26 | Washo; Kenji | Pressure forming process for pressure-formed bamboo products |
US6420034B1 (en) * | 1998-10-13 | 2002-07-16 | Mitsui Chemicals, Inc. | Binder composition and process for manufacturing board by using the binder composition |
US6224800B1 (en) * | 1998-12-17 | 2001-05-01 | Bayer Corporation | Extended polymethylene poly(phenylisocyanate) resin binders for the production of wood composite products |
US6047931A (en) * | 1999-02-15 | 2000-04-11 | Bamboo Fencer, Inc. | Bamboo support base assembled from helical structure |
US6183849B1 (en) * | 1999-09-17 | 2001-02-06 | Exxon Research And Engineering Company | Method for manufacturing composite board using high oil content wax and the composite board made using high oil content wax |
US6689298B2 (en) * | 2000-01-31 | 2004-02-10 | Japan Blower Ind. Co., Ltd. | Bamboo fiber board method |
US6841231B1 (en) * | 2000-08-10 | 2005-01-11 | Masonite Corporation | Fibrous composite article and method of making the same |
US6620459B2 (en) * | 2001-02-13 | 2003-09-16 | Houston Advanced Research Center | Resin-impregnated substrate, method of manufacture and system therefor |
US20050171313A1 (en) * | 2001-02-13 | 2005-08-04 | Colvin John C. | Resin impregnated substrate materials |
US6713168B2 (en) * | 2001-07-12 | 2004-03-30 | J.M. Huber Corporation | Fire retardant wood composite materials |
US6881771B2 (en) * | 2001-08-22 | 2005-04-19 | Bayer Aktiengesellschaft | Process for producing press molded materials |
US6641885B2 (en) * | 2001-11-30 | 2003-11-04 | Wei Rong Dong Guan Bamboo & Wood Products | Complex laminated bamboo board |
US6648363B2 (en) * | 2001-12-05 | 2003-11-18 | Shale Gordon | Composite sports board such as a skateboard deck |
US6772569B2 (en) * | 2002-02-06 | 2004-08-10 | John Landus Bennett | Tongue and groove panel |
US20030150522A1 (en) * | 2002-02-13 | 2003-08-14 | Toshiyuki Suzuki | Process for producing woody composite material |
US20050202226A1 (en) * | 2002-04-03 | 2005-09-15 | Alfonso Branca | Wooden element and method for its manufacture |
US20040062915A1 (en) * | 2002-10-01 | 2004-04-01 | Pabedinskas Arunas Antanas | Reinforced composite structural members |
US20050153150A1 (en) * | 2003-08-27 | 2005-07-14 | Rob Wellwood | Container flooring material and method of manufacture |
US20050075201A1 (en) * | 2003-10-03 | 2005-04-07 | Cullen Stephen M. | Composite bamboo sporting implement |
US20050161852A1 (en) * | 2004-01-27 | 2005-07-28 | Decker Emil G. | Bamboo chip treatment and products |
US20070049152A1 (en) * | 2005-08-31 | 2007-03-01 | Ou Nian-Hua | Panel containing bamboo |
US20070048541A1 (en) * | 2005-08-31 | 2007-03-01 | Ou Nian-Hua | Wood panel containing inner culm flakes |
US7459206B2 (en) * | 2005-08-31 | 2008-12-02 | Huber Engineered Woods Llc | Panel containing highly-cutinized bamboo flakes |
US7625631B2 (en) * | 2005-08-31 | 2009-12-01 | Huber Engineered Woods Llc | Wood panel containing inner culm flakes |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20100113193A1 (en) * | 2008-11-05 | 2010-05-06 | Pinnacle Sports Equipment Co., Inc. | Bamboo bat having fiber-fused core and method of manufacturing the same |
US7771296B2 (en) * | 2008-11-05 | 2010-08-10 | Pinnacle Sports Equipment Co., Inc. | Bamboo bat having fiber-fused core and method of manufacturing the same |
Also Published As
Publication number | Publication date |
---|---|
AR056485A1 (en) | 2007-10-10 |
TW200728570A (en) | 2007-08-01 |
CA2621012A1 (en) | 2007-03-08 |
US20070048542A1 (en) | 2007-03-01 |
CN101277818A (en) | 2008-10-01 |
WO2007027405A2 (en) | 2007-03-08 |
WO2007027405A3 (en) | 2007-11-15 |
CA2621012C (en) | 2010-12-07 |
PE20070440A1 (en) | 2007-04-26 |
US7459206B2 (en) | 2008-12-02 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
CA2621089C (en) | Wood panel containing inner culm flakes | |
US20070049152A1 (en) | Panel containing bamboo | |
US20090263617A1 (en) | Panel containing bamboo | |
US20090075021A1 (en) | Panel containing highly-cutinized bamboo flakes | |
US20070116940A1 (en) | Panel containing bamboo | |
US20070178793A1 (en) | Wood panel with water vapor-permeable polyester layer | |
US20070122616A1 (en) | Panel containing bamboo and cedar | |
US7662465B2 (en) | Wood composite material containing paulownia | |
WO2006071736A2 (en) | Wood composite material containing paulownia | |
WO2006020284A2 (en) | Wood panel | |
US7662457B2 (en) | Wood composite material containing strands of differing densities | |
US20070077445A1 (en) | Panel containing bamboo and fungicide | |
US7553549B2 (en) | Engineered wood boards with reduced VOC emissions | |
US7993736B2 (en) | Wood composite material containing strands of differing densities | |
US7560169B2 (en) | Wood composite material containing balsam fir | |
US20100015390A1 (en) | Wood composite material containing balsam fir | |
US20070120284A1 (en) | Wood composite panel containing diiodomethyl-p-tolylsulfone | |
US20070141317A1 (en) | Wood composite material containing albizzia | |
MX2008004198A (en) | Panel containing bamboo and fungicide |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: HUBER ENGINEERED WOODS LLC, NORTH CAROLINA Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:OU, NIAN-HUA, MR;REEL/FRAME:021868/0723 Effective date: 20081118 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |