초록 ▼

A method of producing a surfaced composite panel of cellulosic particulates, such as wood flakes, involves the application of polymer forming foamable material to at least one of the first and second major surfaces of the panel, contacting said at least one of the first and second surfaces with a pr

A method of producing a surfaced composite panel of cellulosic particulates, such as wood flakes, involves the application of polymer forming foamable material to at least one of the first and second major surfaces of the panel, contacting said at least one of the first and second surfaces with a pressure applying surface to apply pressure thereto, foaming the polymer forming foamable material while pressure is applied and curing the applied foam material to produce a polymeric coating on the panel with the desired surface, which is typically extremely smooth. One or both surfaces may be surface treated in this manner. A skin formed on the surface of the panel is believed to add to the strength and stiffness of the coating on the panel. A wide variety of foaming systems may be used to accomplish this surface treating. By avoiding sanding the surface treated panel, the skin remains intact. The resulting panel, in addition to being extremely smooth as desired, resists water penetration when subjected to water or high humidity conditions. The resulting panel is receptive to adhesives for purposes of securing overlaying materials such as vinyl, reduces formaldehyde emissions when a panel formed of the resin which emits formaldehydes is surface treated.

대표청구항 ▼

[ We claim:] [1.] A method of producing a surfaced composite panel of cellulosic particulates, the panel having first and second major surfaces, the major surfaces having ridge areas and areas between the ridge areas, comprising:applying a polymer forming foamable material to at least one of the fir

[ We claim:] [1.] A method of producing a surfaced composite panel of cellulosic particulates, the panel having first and second major surfaces, the major surfaces having ridge areas and areas between the ridge areas, comprising:applying a polymer forming foamable material to at least one of the first and second major surfaces so as to at least partially coat said at least one of the first and second major surfaces with the polymer forming material;contacting said at least one of the first and second major surfaces with a pressure applying surface to apply pressure to said at least one of the first and second major surfaces; andfoaming the polymer forming foamable material while said at least one of the first and second major surfaces is subjected to pressure;applying sufficient pressure with the pressure applying surface to restrict foaming of the polymer at the ridge areas, so as to form a membrane of polymer at such ridge areas with foamed polymer material in the areas between the ridge areas; andcuring the foamed polymer forming material while pressure is applied by the pressure applying surface, to provide said at least one of the first and second major surfaces with a polymer coating whereby the pressure applying surface imparts the desired surface to said at least one of the first and second major surfaces.