Compressible mat of whole wood fibers and uncured resin as overlay for wood product and process of making same

• US 3,308,013 A
• Filed: 12/07/1965
• Issued: 03/07/1967
• Est. Priority Date: 12/07/1965
• Status: Expired due to Term

• Current Assignee: Benjamin S. Bryant
• Original Assignee: Benjamin S. Bryant
• Inventors: Bryant, Benjamin S.
• Application Number:
  US04/520,018
• Time in Patent Office: 455 Days
• US Class Current: 162/103
• CPC Class Codes: B27N 7/005 Coating boards, e.g. with a finishing or decorating layer
• CPC Class Codes: D21J 1/16 Special fibreboard
• CPC Class Codes: Y10T 428/249941 Fiber is on the surface of a polymeric matrix having no embedded portion
• CPC Class Codes: Y10T 428/253 Cellulosic [e.g., wood, paper, cork, rayon, etc.]
• CPC Class Codes: Y10T 428/3196 Phenoplast

Claims

1. A PROCESS OF MAKING AN OVERLAID WOODY PRODUCT, COMRISING;

SCREEN FORMING A POROUS COMPRESSIBLE MAT CONSISTING ESSENTIALLY OF WHOLE WOOD FIBERS FROM AN AQUEOUS, FIBER SLURRY TO A THICKNESS OF FROM 0.1 TO 0.5 INCH THICK AND A SPECIFIC GRAVITY F FROM 0.15 TO 0.30;

SAID FIBERS HAVING AN UNCURED SYNTHETIC RESIN SOLIDS PRECIPITATED UNIFORMLY THEREON IN AN AMOUNT OF AT LEAST ABOUT 5% BASED ON THE DRY FIBER WEIGHT;

ADJUSTING THE MOISTURE CONTENT OF SAID POROUS MAT TO BETWEEN ABOUT 12% AND 200% BASED ON THE DRY FIBER WEIGHT;

DISPOSING SAID MAT IN FACE TO FACE RELATION TO AN UNCONSOLIDATED SUBSTRATE OF ADHESIVE BEARING WOODY MEMBERS;

CONSOLIDATING SAID SUBSTRATE AND MAT HEAT AND PRESSURE TO CURE THE RESIN AND ADHESIVE CONTENT AND PROVID SAID CURED MAT WITH A SPECIFIC GRAVITY OF BETWEEN ABOUT 0.7 AND 0.95, THEREBY FILLING ANY VOIDS IN THE SURFACE OF SAID SUBSTRATE.