CA1278470C - Method of making fibre mats - Google Patents
Method of making fibre matsInfo
- Publication number
- CA1278470C CA1278470C CA000479423A CA479423A CA1278470C CA 1278470 C CA1278470 C CA 1278470C CA 000479423 A CA000479423 A CA 000479423A CA 479423 A CA479423 A CA 479423A CA 1278470 C CA1278470 C CA 1278470C
- Authority
- CA
- Canada
- Prior art keywords
- fibres
- fibre
- air
- amount
- phenol resin
- 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.)
- Expired - Fee Related
Links
Classifications
-
- 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
- B27N3/08—Moulding or pressing
- B27N3/10—Moulding of mats
- B27N3/14—Distributing or orienting the particles or fibres
Landscapes
- Life Sciences & Earth Sciences (AREA)
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Wood Science & Technology (AREA)
- Forests & Forestry (AREA)
- Paper (AREA)
- Laminated Bodies (AREA)
- Multicomponent Fibers (AREA)
- Dry Formation Of Fiberboard And The Like (AREA)
- Nonwoven Fabrics (AREA)
- Reinforced Plastic Materials (AREA)
Abstract
Abstract For use as carcass in laminates a mat of fibrous material is manufactured by exposing and impregnating the fibres. The fibres are thereafter dried and formed into a web by being deposited on a movable belt or "wire". The final forming of the web to a fibre mat is carried out by pressing in at least one step.
Description
7~
This invention relates to a method of making fibre mats -to be used as a carcass in a laminate by impregnating and forming of fibre material.
The desired laminate consists of a carcass and surface layers and may have a technical as well as a decor-ative function. The carcass in the laminate is made from a number of sheets of kraf-t paper which have been impregnated, preferably with phenol resin. For laminates of great thick-ness which are used as load-carrying structures, a large number of paper sheets should be used.
With this -type of laminate, thus, paper sheets must first be manufactured which thereafter are impregnated and assembled. To make a detour in -this way over paper is a process which requires both energy and labour. A simplified method,therefore, would also imply essential economic advantages.
The present invention renders it possible that the manufacture of the laminate can be carried out in a simpler and less expensive way. The carcass or carrying structure in the laminate can be made in the form of a fibre mat directly from the fibre material, so that no paper sheets are required. The fibre material can be of various kinds, for example cellulose fibres or artificial fibres, but preferably fibres of cellulose-containing material are used.
The method oE the invention may be generally defined as a method of manufacturing mats of fibrous material for use ~%7~
,~
as a carcass in a laminate, characterized in ~hat ~he ~sthod comprises ~he follo~ing steps:
a~ separating single fibres from the ~ibrous material by refining of wood chips, b) impregnation of the fibres wi~h a binder containing phenol resin in an amount of 10-50% by weight of the fibre directly after the refining in a transport conduit where hi~h speed and turbulence prevail, c) drying of the fibres by ho~ air in an air transport conduit, d) separation of the air from the ~ibres, e~ forming of a web of the fibres by uniformly distributing and dep3siting the fibres on a mova~le belt, and f) final forming of the fibre ~eb ~o a fibre mat by pressing in at least one step.
The invention is described in greater detail in the following with reference to the accompanying Figure, which is a flow chart for one embodiment of the method accordin~ to tha invention.
According to khe embodiment shown in the drawing the starting material is wood chips. They are washed in a chip washer 1 and thereafter fed into a refiner 2 via a preheater 3. The refiner 2 is of the disc-refiner type having a pressurized refiner housing g. The object is to manufacture a fibre pulp which is substantially free of shives. Throuyh a blow conduit 5 coupled to ~Z7~341170 the refiner housing 4 the refined fibre ma~erial i~ transportad by means of overpressure in the refiner housing 4. Impragnation chemicals are added in the blow conduit 5 and/or immediately prior to the refining. The ~.~
7~3~7~
chemicals include a suitable binder such as phenol resin in an amount of 10-50, and preferably 20-50%, by weight of the fibre.
A small amount of paraffin, up to 2%, may be added simult-aneously with the phenol resin.
The impregnation chemicals preferably are supplied in the blow conduit 5 where high speed and turbulence prevail in the fibre pulp, whereby the resin is effectively distributed on the single fibres.
The impregnated fibre material is transferred from the blow conduit 5 to a drier 6, which comprises a fan 7 and a heating device 8 for heating air to a temperature below the curing temperature of the phenol resin (at maximum 200C, preferably ~elow 160C). The hot air and the fibre pulp are transported through a drier pipe 9, in which the drying takes place. The residence time in the drier pipe 9 is very short.
By controlling the air temperature and residence time, -the desired dry content of the fibre material can be obtained.
~ In the drier pipe 9, the sol~ent supplied with the impregnation; medium and the fibre moisture are both evaporated.
The drier pipe 9 opens into a cyclone 10 where air and fibres are separated. The air leaving the cyclone normally has a temperature between 60 and 85C. Depending on the impregnation chemicals used, this air also can contain substances which must not be emitted freely. When phenol resin is used gases are released during the drying which in certain cases must be recovered. Part of the air can then be 7~
recirculated to the inlet of the drier fan 7, and the remaining part is directed to combustion. To prevent the gas components which are deemed dangerous from doing harm a temperature of 600C is required. Suitable equipment for this purpose is commercially available.
The fibre material separated in the cyclone 10 is weighed on a pair of fibre scales 11, preferably of the belt weigher type. The fibre amount weighed determines the amount of impregnation agent which should be supplied. The fibre material is transported from the fibre scales 11 via an air transport conduit to a storage container 12, into which the fibre material is fed via an air separation cyclone 13. From said container 12 the fibre material is ~assed by means of an air transport conduit to a forming station 14, for example of the type shown in SE-PS 7510795-3.
The forming station 14 can be a pneumatic or mechanical one and is adjustable to different thicknesses. The forming station 14 comprises a distribution chamber 15 and a conveyor belt 16 in the form of a wire, on which the fibres are deposited. The -transport air is sucked -through the belt by means of a fan 17. An additional cyclone 18 provided with fans serves to separate and return the entrained fibres, which fibres are subjected to repeated distribution at the forming station 14. This arrangement insures that the mat formed can meet reasonable requirements with respect to forming accuracy (surface layer variations).
7~
The forming is followed by a continuous prepressing in a press 19. Preferably a belt prepress of conventional design is used for removing remaining air from the fibre mat and for consolidating the mat so that it can be handled in subsequent process steps. Loose fibres are also returned from the prepressing to be used again at the forming station 14.
The fibre mat is thereafter divided into desired dimensions by means of longitudinal and transverse saws 20 and 21, respectively. A metal detector 22 is preferably located adjacent to the saws. Depending on the aperture of the laminate press (not shown) subsequen-t to the saws and on the capacity of said press, a plate prepress may also be provided before the laminate press. In any such prepress heat may be supplied to the fibre mat in order to shorten the heating time in the subsequent laminate press.
Fibre mats, which are rejected, for example because of non-uniform forming at the start, are passed to a return bin 22 where the material is torn up and returned to the process. In cases when the fibres cannot be reused directly, for example when they contain metal, the fibre material is passed to a special reject container for treatment.
The invention is not, of course, restricted to the embodiment shown, but can be varied within the scope of the appended claims.
This invention relates to a method of making fibre mats -to be used as a carcass in a laminate by impregnating and forming of fibre material.
The desired laminate consists of a carcass and surface layers and may have a technical as well as a decor-ative function. The carcass in the laminate is made from a number of sheets of kraf-t paper which have been impregnated, preferably with phenol resin. For laminates of great thick-ness which are used as load-carrying structures, a large number of paper sheets should be used.
With this -type of laminate, thus, paper sheets must first be manufactured which thereafter are impregnated and assembled. To make a detour in -this way over paper is a process which requires both energy and labour. A simplified method,therefore, would also imply essential economic advantages.
The present invention renders it possible that the manufacture of the laminate can be carried out in a simpler and less expensive way. The carcass or carrying structure in the laminate can be made in the form of a fibre mat directly from the fibre material, so that no paper sheets are required. The fibre material can be of various kinds, for example cellulose fibres or artificial fibres, but preferably fibres of cellulose-containing material are used.
The method oE the invention may be generally defined as a method of manufacturing mats of fibrous material for use ~%7~
,~
as a carcass in a laminate, characterized in ~hat ~he ~sthod comprises ~he follo~ing steps:
a~ separating single fibres from the ~ibrous material by refining of wood chips, b) impregnation of the fibres wi~h a binder containing phenol resin in an amount of 10-50% by weight of the fibre directly after the refining in a transport conduit where hi~h speed and turbulence prevail, c) drying of the fibres by ho~ air in an air transport conduit, d) separation of the air from the ~ibres, e~ forming of a web of the fibres by uniformly distributing and dep3siting the fibres on a mova~le belt, and f) final forming of the fibre ~eb ~o a fibre mat by pressing in at least one step.
The invention is described in greater detail in the following with reference to the accompanying Figure, which is a flow chart for one embodiment of the method accordin~ to tha invention.
According to khe embodiment shown in the drawing the starting material is wood chips. They are washed in a chip washer 1 and thereafter fed into a refiner 2 via a preheater 3. The refiner 2 is of the disc-refiner type having a pressurized refiner housing g. The object is to manufacture a fibre pulp which is substantially free of shives. Throuyh a blow conduit 5 coupled to ~Z7~341170 the refiner housing 4 the refined fibre ma~erial i~ transportad by means of overpressure in the refiner housing 4. Impragnation chemicals are added in the blow conduit 5 and/or immediately prior to the refining. The ~.~
7~3~7~
chemicals include a suitable binder such as phenol resin in an amount of 10-50, and preferably 20-50%, by weight of the fibre.
A small amount of paraffin, up to 2%, may be added simult-aneously with the phenol resin.
The impregnation chemicals preferably are supplied in the blow conduit 5 where high speed and turbulence prevail in the fibre pulp, whereby the resin is effectively distributed on the single fibres.
The impregnated fibre material is transferred from the blow conduit 5 to a drier 6, which comprises a fan 7 and a heating device 8 for heating air to a temperature below the curing temperature of the phenol resin (at maximum 200C, preferably ~elow 160C). The hot air and the fibre pulp are transported through a drier pipe 9, in which the drying takes place. The residence time in the drier pipe 9 is very short.
By controlling the air temperature and residence time, -the desired dry content of the fibre material can be obtained.
~ In the drier pipe 9, the sol~ent supplied with the impregnation; medium and the fibre moisture are both evaporated.
The drier pipe 9 opens into a cyclone 10 where air and fibres are separated. The air leaving the cyclone normally has a temperature between 60 and 85C. Depending on the impregnation chemicals used, this air also can contain substances which must not be emitted freely. When phenol resin is used gases are released during the drying which in certain cases must be recovered. Part of the air can then be 7~
recirculated to the inlet of the drier fan 7, and the remaining part is directed to combustion. To prevent the gas components which are deemed dangerous from doing harm a temperature of 600C is required. Suitable equipment for this purpose is commercially available.
The fibre material separated in the cyclone 10 is weighed on a pair of fibre scales 11, preferably of the belt weigher type. The fibre amount weighed determines the amount of impregnation agent which should be supplied. The fibre material is transported from the fibre scales 11 via an air transport conduit to a storage container 12, into which the fibre material is fed via an air separation cyclone 13. From said container 12 the fibre material is ~assed by means of an air transport conduit to a forming station 14, for example of the type shown in SE-PS 7510795-3.
The forming station 14 can be a pneumatic or mechanical one and is adjustable to different thicknesses. The forming station 14 comprises a distribution chamber 15 and a conveyor belt 16 in the form of a wire, on which the fibres are deposited. The -transport air is sucked -through the belt by means of a fan 17. An additional cyclone 18 provided with fans serves to separate and return the entrained fibres, which fibres are subjected to repeated distribution at the forming station 14. This arrangement insures that the mat formed can meet reasonable requirements with respect to forming accuracy (surface layer variations).
7~
The forming is followed by a continuous prepressing in a press 19. Preferably a belt prepress of conventional design is used for removing remaining air from the fibre mat and for consolidating the mat so that it can be handled in subsequent process steps. Loose fibres are also returned from the prepressing to be used again at the forming station 14.
The fibre mat is thereafter divided into desired dimensions by means of longitudinal and transverse saws 20 and 21, respectively. A metal detector 22 is preferably located adjacent to the saws. Depending on the aperture of the laminate press (not shown) subsequen-t to the saws and on the capacity of said press, a plate prepress may also be provided before the laminate press. In any such prepress heat may be supplied to the fibre mat in order to shorten the heating time in the subsequent laminate press.
Fibre mats, which are rejected, for example because of non-uniform forming at the start, are passed to a return bin 22 where the material is torn up and returned to the process. In cases when the fibres cannot be reused directly, for example when they contain metal, the fibre material is passed to a special reject container for treatment.
The invention is not, of course, restricted to the embodiment shown, but can be varied within the scope of the appended claims.
Claims (3)
1. A method of manufacturing mats of fibrous material for use as a carcass in a laminate, characterized in that the method comprises the following steps:
a) separating single fibres from the fibrous material by refining of wood chips, b) impregnation of the fibres with a binder containing phenol resin in an amount of 10-50% by weight of the fibre directly after the refining in a transport conduit where high speed and turbulence prevail, c) drying of the fibres by hot air in an air transport conduit, d) separation of the air from the fibres, e) forming of a web of the fibres by uniformly distributing and depositing the fibres on a movable belt, and f) final forming of the fibre web to a fibre mat by pressing in at least one step.
a) separating single fibres from the fibrous material by refining of wood chips, b) impregnation of the fibres with a binder containing phenol resin in an amount of 10-50% by weight of the fibre directly after the refining in a transport conduit where high speed and turbulence prevail, c) drying of the fibres by hot air in an air transport conduit, d) separation of the air from the fibres, e) forming of a web of the fibres by uniformly distributing and depositing the fibres on a movable belt, and f) final forming of the fibre web to a fibre mat by pressing in at least one step.
2. A method as defined in claim 1, characterized in that the binder contains phenol resin in an amount of 20-50% by weight of the fibre.
3. A method as defined in claim 1, characterized in that the amount of added binder is monitored by weighing the material immediately after the air separation according to step (d) of claim 1.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| SE8402418A SE446996B (en) | 1984-05-04 | 1984-05-04 | PROCEDURE FOR MANUFACTURING MATERIAL OF FIBER MATERIAL FOR USING LAMINATE FILM |
| SE8402418-1 | 1984-05-04 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1278470C true CA1278470C (en) | 1991-01-02 |
Family
ID=20355758
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000479423A Expired - Fee Related CA1278470C (en) | 1984-05-04 | 1985-04-18 | Method of making fibre mats |
Country Status (11)
| Country | Link |
|---|---|
| EP (1) | EP0211842A1 (en) |
| JP (1) | JPS61502046A (en) |
| AU (1) | AU579629B2 (en) |
| BR (1) | BR8507181A (en) |
| CA (1) | CA1278470C (en) |
| DK (1) | DK158237C (en) |
| FI (1) | FI864465A (en) |
| NO (1) | NO860014L (en) |
| NZ (1) | NZ211528A (en) |
| SE (1) | SE446996B (en) |
| WO (1) | WO1985005065A1 (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| SE461962B (en) * | 1987-12-16 | 1990-04-23 | Sunds Defibrator Ind Ab | SET AND DEVICE FOR MANUFACTURING FIBER BOARD DISKS |
Family Cites Families (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3371137A (en) * | 1968-02-27 | Defibrator Ab | Method in the manufacture of fiber board | |
| US2912041A (en) * | 1954-01-28 | 1959-11-10 | H D Boggs Company Ltd | Core compactor |
| US3071822A (en) * | 1959-03-03 | 1963-01-08 | Bowater Board Company | Method and apparatus for forming a mat |
| US3494992A (en) * | 1968-02-01 | 1970-02-10 | Conwed Corp | Method of producing a mat from an air suspension of fibers and liquid |
| US3642554A (en) * | 1970-02-16 | 1972-02-15 | Certain Teed Prod Corp | Closed mat forming system |
-
1984
- 1984-05-04 SE SE8402418A patent/SE446996B/en not_active IP Right Cessation
-
1985
- 1985-03-21 NZ NZ211528A patent/NZ211528A/en unknown
- 1985-04-01 AU AU42192/85A patent/AU579629B2/en not_active Ceased
- 1985-04-01 BR BR8507181A patent/BR8507181A/en unknown
- 1985-04-01 WO PCT/SE1985/000153 patent/WO1985005065A1/en not_active Application Discontinuation
- 1985-04-01 JP JP60501765A patent/JPS61502046A/en active Pending
- 1985-04-01 EP EP85902177A patent/EP0211842A1/en not_active Withdrawn
- 1985-04-18 CA CA000479423A patent/CA1278470C/en not_active Expired - Fee Related
- 1985-12-09 DK DK568085A patent/DK158237C/en not_active IP Right Cessation
-
1986
- 1986-01-03 NO NO860014A patent/NO860014L/en unknown
- 1986-11-03 FI FI864465A patent/FI864465A/en not_active Application Discontinuation
Also Published As
| Publication number | Publication date |
|---|---|
| AU4219285A (en) | 1985-11-28 |
| FI864465A0 (en) | 1986-11-03 |
| WO1985005065A1 (en) | 1985-11-21 |
| DK158237C (en) | 1990-09-24 |
| BR8507181A (en) | 1987-04-22 |
| DK158237B (en) | 1990-04-16 |
| NZ211528A (en) | 1987-02-20 |
| EP0211842A1 (en) | 1987-03-04 |
| AU579629B2 (en) | 1988-12-01 |
| FI864465A (en) | 1986-11-03 |
| DK568085A (en) | 1985-12-09 |
| JPS61502046A (en) | 1986-09-18 |
| SE446996B (en) | 1986-10-20 |
| NO860014L (en) | 1986-01-03 |
| DK568085D0 (en) | 1985-12-09 |
| SE8402418L (en) | 1985-11-05 |
| SE8402418D0 (en) | 1984-05-04 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| US2757150A (en) | Preparing hot-moldable thermosetting resin and cellulose fiber mixtures | |
| EP0092699B1 (en) | Blow line addition of isocyanate binder in fiberboard manufacture | |
| US3021244A (en) | Process for producing high density hardboard | |
| US2872337A (en) | Method of coating a felted fibrous mat | |
| CA1053557A (en) | Method of making laminar material having a base of bonded wood particles | |
| US4597930A (en) | Method of manufacture of a felted fibrous product from a nonaqueous medium | |
| US4379808A (en) | Sheet type forming board and formed board products | |
| US3533906A (en) | Permanently reacted lignocellulose products and process for making the same | |
| FI72926B (en) | DECORATIVE LAMINATE SOM HAR FRAMSTAELLTS GENOM ANVAENDNING AV HOEGT TRYCK OCH INNEHAOLLER LUFTLAGD BANA SAMT FOERFARANDE FOER FRAMSTAELLNING AV DENNA. | |
| US5558933A (en) | Sheeting material and method of manufacturing the same | |
| NO134865B (en) | ||
| US4311555A (en) | Method of manufacturing fiberboard | |
| CA1278470C (en) | Method of making fibre mats | |
| US6868877B2 (en) | Method for producing a processed continuous veneer ribbon and consolidated processed veneer strand product therefrom | |
| US2876153A (en) | Synthetic board and method of manufacture | |
| CA1054414A (en) | Short cycle pressed fibreboard manufacturing process | |
| US3130114A (en) | Process of manufacturing fibreboards and pressings from lignocellulose material | |
| US3801434A (en) | Method in the manufacture of lignocellulosic fibreboard | |
| US2925360A (en) | Method of preventing excessive springback of dry felted fiber mats | |
| US2798019A (en) | Structural board | |
| EP2420616B1 (en) | Method and assembly for preparing wood for the production of medium thickness fibre boards | |
| EP0182949B1 (en) | Method for making boards or articles from lignocellulosic fibres | |
| CA2058541A1 (en) | Fibrous component for paper production, paper made therewith and use thereof and method for producing fibrous component and paper | |
| FI70606B (en) | FOERFARANDE OCH ANORDNING FOER FRAMSTAELLNING AV MEKANISK MASSA | |
| Lewis et al. | Insulating board, hardboard, and other structural fiberboards |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKLA | Lapsed |