IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
UP-0941644
(2004-09-15)
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등록번호 |
US-7640664
(2010-02-11)
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발명자
/ 주소 |
- Bailey, Stephen B.
- Schoneberger, Michael C.
|
출원인 / 주소 |
|
대리인 / 주소 |
Schwegman, Lundberg & Woessner, P.A.
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인용정보 |
피인용 횟수 :
4 인용 특허 :
6 |
초록
The present invention provides a wood-based composite panel that is not susceptible to top surface edge swell, and methods of making the panel.
대표청구항
▼
What is claimed is: 1. A process for manufacturing a wood-based composite panel that is not susceptible to top surface edge swell, the process comprising: (i) contacting flakes of wood with a first resin; (ii) orienting, in substantially alternate lengthwise and crosswise layers, the flakes of wood
What is claimed is: 1. A process for manufacturing a wood-based composite panel that is not susceptible to top surface edge swell, the process comprising: (i) contacting flakes of wood with a first resin; (ii) orienting, in substantially alternate lengthwise and crosswise layers, the flakes of wood to provide a blanket of substantially oriented flakes; (iii) curing the first resin by exposing the first resin to at least one of an elevated temperature, an elevated pressure, and radiant energy for a sufficient period of time to effectively cure the first resin, thereby effectively providing a wood-based composite panel having a substantially level top surface and a substantially level bottom surface; and (iv) removing a top surface edge portion of the panel, thereby providing a panel that is not susceptible to top surface edge swell and having a top surface defined by a plurality of top surface sides, at least one of which having a size less than a size of a corresponding bottom surface side. 2. The process of claim 1 wherein the elevated temperature is about 162° C. (325° F.) to about 246° C. (475° F.). 3. The process of claim 1 wherein the elevated temperature is about 177° C. (350° F.) to about 232° C. (450° F.). 4. The process of claim 1 wherein the elevated temperature is about 191° C. (375° F.) to about 218° C. (425° F.). 5. The process of claim 1 wherein the elevated pressure is about 25 atm. (367 psi) to about 55 atm. (808 psi). 6. The process of claim 1 wherein the elevated pressure is about 30 atm. (441 psi) to about 50 atm. (735 psi). 7. The process of claim 1 wherein the elevated pressure is about 34 atm. (500 psi) to about 48 atm. (705 psi). 8. The process of claim 1 wherein the elevated pressure is about 35 atm. (514 psi) to about 45 atm. (661 psi). 9. The process of claim 1 wherein the sufficient period of time is up to about 10.0 minutes. 10. The process of claim 1 wherein the sufficient period of time is about 3.0 minutes to about 9.0 minutes. 11. The process of claim 1 wherein the radiant energy is UV light. 12. The process of claim 1 wherein the radiant energy is electron beam. 13. The process of claim 1 wherein the radiant energy is neutron beam. 14. The process of claim 1 wherein the radiant energy is proton beam. 15. The process of claim 1 wherein the radiant energy is microwave. 16. The process of claim 1 wherein the radiant energy is beta radiation. 17. The process of claim 1 wherein the radiant energy is gamma radiation. 18. The process of claim 1 wherein the radiant energy is infra red. 19. The process of claim 1 wherein the radiant energy is radio frequency. 20. The process of claim 1 wherein removing the top surface edge portion comprises a least one of sanding, cutting and shaving. 21. The process of claim 1 wherein removing the top surface edge portion of the panel provides a side surface defined by a plurality of side surface sides, at least one of which is reduced from a pre-edge removal size. 22. The process of claim 21 wherein the size reduction of the at least one side surface side is at least about 1/1000 inch. 23. The process of claim 21 wherein the size reduction of the at least one side surface side is at least about 5/1000 inch. 24. The process of claim 21 wherein the size reduction of the at least one side surface side is up to about 1/10 inch. 25. The process of claim 21 wherein the size reduction of the at least one side surface side is about 1/1000 inch to about 1/10 inch. 26. The process of claim 21 wherein the size reduction of the at least one side surface side is about 5/1000 inch to about 20/1000 inch. 27. The process of claim 1 wherein the size difference between the at least one top surface side and the corresponding bottom surface side is up to 2 inches. 28. The process of claim 1 wherein the size difference between the at least one top surface side and the corresponding bottom surface side is up to 1 inch. 29. The process of claim 1 wherein the size difference between the at least one top surface side and the corresponding bottom surface side is up to 15/16 inch. 30. The process of claim 1 wherein the size difference between the at least one top surface side and the corresponding bottom surface side is up to ⅞ inch. 31. The process of claim 1 wherein the size difference between the at least one top surface side and the corresponding bottom surface side is about ⅛ inch to about ¾ inch. 32. The process of claim 1 wherein the size difference between the at least one top surface side and the corresponding bottom surface side is about ⅜ inch to about ¾ inch. 33. The process of claim 1 wherein the size difference between the at least one top surface side and the corresponding bottom surface side is more than 1/16 inch. 34. The process of claim 1 wherein the size difference between the at least one top surface side and the corresponding bottom surface side is more than ⅛ inch. 35. The process of claim 1 wherein the size difference between the at least one top surface side and the corresponding bottom surface side is more than ⅜ inch. 36. The process of claim 1 wherein removing the top surface edge portion includes forming a non-uniform edged plane on one side of the panel. 37. The process of claim 1 wherein removing the top surface edge portion includes forming a non-uniform edged plane on more than one side of the panel. 38. The process of claim 1 wherein removing the top surface edge portion includes forming a non-uniform edged plane on two sides of the panel. 39. The process of claim 1 wherein removing the top surface edge portion includes forming a non-uniform edged plane on three sides of the panel. 40. The process of claim 1 wherein removing the top surface edge portion includes forming a non-uniform edged plane on four sides of the panel. 41. The process of claim 1 wherein the panel comprises flakes of wood adhered together with a first resin. 42. The process of claim 1 wherein the panel comprises flakes that are sized with a hydrocarbon wax selected from the group of paraffinic wax, microcrystalline wax, and mixtures thereof. 43. The process of claim 1 wherein the panel comprises a thermosetting polymer. 44. The process of claim 1 wherein the panel comprises a thermosetting polymer selected from the group of a phenolic resin, a formaldehyde resin, a resorcinolic resin, a melamine resin, an isocyanate resin, a urea resin, an epoxy resin, a phenol-formaldehyde (PF) resin, a melamine-formaldehyde (MF) resin, a phenol-melamine-formaldehyde (PMF) resin, and combinations thereof. 45. The process of claim 1 wherein the panel comprises a phenol-melamine-formaldehyde (PMF) resin. 46. The process of claim 1 wherein the panel further comprises a catalyst to assist in curing a resin. 47. The process of claim 1 wherein the panel is configured for tongue and grove fitting. 48. The process of claim 1 wherein the panel has a moisture vapor permeability of up to about 0.025 g/hr-m2-mm Hg. 49. The process of claim 1 wherein the panel has a moisture vapor permeability of up to about 0.0005 g/hr-m2-mm Hg. 50. The process of claim 1 wherein the panel further comprises at least one of a colorant, dye and indicator. 51. The process of claim 1 wherein the panel comprises up to about 15 plies. 52. The process of claim 1 wherein the panel comprises up to about 15 plies and wherein the plies have a ratio of up to about five piles per ½ inch of total wood-based composite panel width. 53. The process of claim 1 wherein the panel is fire retardant. 54. The process of claim 1 wherein the panel further comprises a fire retardant. 55. The process of claim 1 wherein the panel is moisture resistant. 56. The process of claim 1 wherein the panel is mold resistant. 57. The process of claim 1 wherein the panel further comprises an anti-fungal agent. 58. The process of claim 1 wherein the panel is termite resistant. 59. The process of claim 1 wherein the panel further comprises a pesticide. 60. The process of claim 1 wherein the panel is resistant to insect infestation. 61. The process of claim 1 wherein the panel further comprises an anti-mold agent. 62. The process of claim 1 wherein the panel is manufactured from a Western species of timber. 63. The process of claim 1 wherein the panel is manufactured from a Northern species of timber. 64. The process of claim 1 wherein the panel is manufactured from an Appalachian species of timber. 65. The process of claim 1 wherein the panel is manufactured from a Southern species of timber. 66. The process of claim 1 wherein the panel is manufactured from at least one of Incense-Cedar, Port-Orford-Cedar, Douglas Fir, White Fir, Western Hemlock, Western Larch, Lodgepole Pine, Ponderosa Pine, Sugar Pine, Western White Pine, Western Redcedar, Redwood, Engelmann Spruce, Sitka Spruce, Yellow-Cedar, Red Alder, Oregon Ash, Aspen, Black Cottonwood, California Black Oak, Oregon White Oak, Big Leaf Maple, Paper Birch, and Tanoak. 67. The process of claim 1 wherein the panel is manufactured from at least one of Northern White Cedar, Balsam Fir, Eastern Hemlock, Fraser Fir, Jack Pine, Red Pine, Eastern White Pine, Eastern Red Cedar, Eastern Spruce, Tamarack, Ash, Aspen, Basswood, Buckeye, Butternut, American Beech, Birch, Black Cherry, American Chestnut, Cottonwood, Elm, Hack Berry, True Hickory, Honey Locust, Black Locust, Hard Maple, Soft Maple, Red Oak, White Oak, American Sycamore, Black Walnut, and Yellow-Poplar. 68. The process of claim 1 wherein the panel is manufactured from at least one of Atlantic White Cedar, Bald Cypress, Fraser Fir, Southern Pine, Eastern Red Cedar, Ash, Basswood, Arnecan, Beech, Butternut, Cottonwood, Elm, Hackberry, Pecan Hickory, True Hickory, Honey Locust, Black Locust, Magnolia, Soft Maple, Red Oak, Sassafras, Sweetgum, American Sycamore, Tupelo, Black Walnut, Black Willow, and Yellow Poplar. 69. The process of claim 1 wherein the flakes of wood have a length of up to about 12 inches (30.5 cm). 70. The process of claim 1 wherein the flakes of wood have a length of about 4.0 inches (10.2 cm.) to about 6.0 inches (15.2 cm). 71. The process of claim 1 wherein the flakes of wood have a width of up to about 12 inches (30.5 cm). 72. The process of claim 1 wherein the flakes of wood have a width of about 1.5 inches (3.8 cm) to about 2.5 inches (6.4 cm). 73. The process of claim 1 wherein the flakes of wood have a width of up to about 0.25 inches (0.64 cm). 74. The process of claim 1 wherein the flakes of wood have a width of about 0.020 inches (0.051 cm) to about 0.030 inches (0.076 cm). 75. The process of claim 1 wherein the flakes of wood have a strand length divided by strand width of at least 3.0. 76. The process of claim 1 wherein the first resin substantially covers the entire surface of the flakes of wood. 77. The process of claim 1 wherein the first resin impregnates the flakes of wood. 78. The process of claim 1 wherein the first resin completely impregnates the flake of wood. 79. The process of claim 1 wherein the first resin partially impregnates the flakes of wood. 80. The process of claim 1 wherein the first resin impregnates up to about 1/10 of the flakes of wood. 81. The process of claim 1 wherein the first resin impregnates up to about ¼ of the flakes of wood. 82. The process of claim 1 wherein the first resin impregnates up to about ½ of the flakes of wood. 83. The process of claim 1 wherein the first resin impregnates up to about ¾ of the flakes of wood. 84. The process of claim 1 wherein the first resin impregnates up to about 99/100 of the flakes of wood. 85. The process of claim 1 wherein the first resin impregnates about 1/20 to about ½ the flakes of wood. 86. The process of claim 1 wherein the first resin covers at least about 60% of the surface of the flakes of wood. 87. The process of claim 1 wherein the first resin covers at least about 70% of the surface of the flakes of wood. 88. The process of claim 1 wherein the first resin covers at least about 80% of the surface of the flakes of wood. 89. The process of claim 1 wherein the first resin covers at least about 90% of the surface of the flakes of wood. 90. The process of claim 1 wherein the panel is used in residential sheathing, light frame wall sheathing, roof sheathing, sub-flooring applications, siding, furniture, flooring, trim, wall covering, or roofing. 91. The process of claim 1 wherein the panel is edge sealed. 92. The process of claim 1 wherein the panel is pre-primed. 93. The process of claim 1 wherein the removed top surface edge portion accommodates any expansion of the panel. 94. The process of claim 1 wherein at least one of the top surface sides is equal in size to a corresponding bottom surface side.
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