EP2978910A1 - Hybrid wood products - Google Patents
Hybrid wood productsInfo
- Publication number
- EP2978910A1 EP2978910A1 EP14722915.7A EP14722915A EP2978910A1 EP 2978910 A1 EP2978910 A1 EP 2978910A1 EP 14722915 A EP14722915 A EP 14722915A EP 2978910 A1 EP2978910 A1 EP 2978910A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- product
- wood
- layer
- pine
- fiberboard
- 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.)
- Withdrawn
Links
- 239000011186 hybrid wood Substances 0.000 title claims abstract description 6
- 239000011094 fiberboard Substances 0.000 claims abstract description 28
- 239000000758 substrate Substances 0.000 claims abstract description 25
- 229920001587 Wood-plastic composite Polymers 0.000 claims abstract description 5
- 239000002131 composite material Substances 0.000 claims abstract description 5
- 239000011155 wood-plastic composite Substances 0.000 claims abstract description 5
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 claims abstract description 4
- 229920002554 vinyl polymer Polymers 0.000 claims abstract description 4
- 239000002023 wood Substances 0.000 claims description 93
- 239000000463 material Substances 0.000 claims description 21
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 claims description 12
- 235000017166 Bambusa arundinacea Nutrition 0.000 claims description 8
- 235000017491 Bambusa tulda Nutrition 0.000 claims description 8
- 241000758789 Juglans Species 0.000 claims description 8
- 235000009496 Juglans regia Nutrition 0.000 claims description 8
- 244000082204 Phyllostachys viridis Species 0.000 claims description 8
- 235000015334 Phyllostachys viridis Nutrition 0.000 claims description 8
- 235000008331 Pinus X rigitaeda Nutrition 0.000 claims description 8
- 241000018646 Pinus brutia Species 0.000 claims description 8
- 235000011613 Pinus brutia Nutrition 0.000 claims description 8
- 239000011425 bamboo Substances 0.000 claims description 8
- 239000011122 softwood Substances 0.000 claims description 8
- 235000020234 walnut Nutrition 0.000 claims description 8
- 240000007320 Pinus strobus Species 0.000 claims description 7
- 239000000853 adhesive Substances 0.000 claims description 7
- 230000001070 adhesive effect Effects 0.000 claims description 7
- 229920005989 resin Polymers 0.000 claims description 7
- 239000011347 resin Substances 0.000 claims description 7
- 244000283070 Abies balsamea Species 0.000 claims description 6
- 235000007173 Abies balsamea Nutrition 0.000 claims description 6
- 241000167854 Bourreria succulenta Species 0.000 claims description 6
- 241000218691 Cupressaceae Species 0.000 claims description 6
- 235000014466 Douglas bleu Nutrition 0.000 claims description 6
- 235000008578 Pinus strobus Nutrition 0.000 claims description 6
- 240000001416 Pseudotsuga menziesii Species 0.000 claims description 6
- 235000005386 Pseudotsuga menziesii var menziesii Nutrition 0.000 claims description 6
- 239000011230 binding agent Substances 0.000 claims description 6
- 235000019693 cherries Nutrition 0.000 claims description 6
- 235000005018 Pinus echinata Nutrition 0.000 claims description 5
- 240000004731 Acer pseudoplatanus Species 0.000 claims description 4
- 235000002754 Acer pseudoplatanus Nutrition 0.000 claims description 4
- 240000004144 Acer rubrum Species 0.000 claims description 4
- 235000011772 Acer rubrum var tomentosum Nutrition 0.000 claims description 4
- 235000009057 Acer rubrum var tridens Nutrition 0.000 claims description 4
- 235000002629 Acer saccharinum Nutrition 0.000 claims description 4
- 244000046139 Acer saccharum Species 0.000 claims description 4
- 235000004421 Acer saccharum Nutrition 0.000 claims description 4
- 244000189108 Betula alleghaniensis Species 0.000 claims description 4
- 235000018199 Betula alleghaniensis var. alleghaniensis Nutrition 0.000 claims description 4
- 235000018198 Betula alleghaniensis var. macrolepis Nutrition 0.000 claims description 4
- 235000010910 Betula neoalaskana Nutrition 0.000 claims description 4
- 244000274847 Betula papyrifera Species 0.000 claims description 4
- 241001156387 Carapa guianensis Species 0.000 claims description 4
- 235000014036 Castanea Nutrition 0.000 claims description 4
- 241001070941 Castanea Species 0.000 claims description 4
- 241001166990 Dalbergia retusa Species 0.000 claims description 4
- 241001233195 Eucalyptus grandis Species 0.000 claims description 4
- 240000001414 Eucalyptus viminalis Species 0.000 claims description 4
- 235000013366 Eucalyptus viminalis Nutrition 0.000 claims description 4
- 244000222296 Fagus americana Species 0.000 claims description 4
- 235000018241 Fagus americana Nutrition 0.000 claims description 4
- 235000013740 Juglans nigra Nutrition 0.000 claims description 4
- 244000184861 Juglans nigra Species 0.000 claims description 4
- 241000721662 Juniperus Species 0.000 claims description 4
- 241000557752 Khaya Species 0.000 claims description 4
- 241000218652 Larix Species 0.000 claims description 4
- 235000005590 Larix decidua Nutrition 0.000 claims description 4
- 241000219071 Malvaceae Species 0.000 claims description 4
- 241000158728 Meliaceae Species 0.000 claims description 4
- 240000007182 Ochroma pyramidale Species 0.000 claims description 4
- 244000193463 Picea excelsa Species 0.000 claims description 4
- 235000008124 Picea excelsa Nutrition 0.000 claims description 4
- 241001236219 Pinus echinata Species 0.000 claims description 4
- 235000011334 Pinus elliottii Nutrition 0.000 claims description 4
- 241000218617 Pinus monticola Species 0.000 claims description 4
- 235000017339 Pinus palustris Nutrition 0.000 claims description 4
- 235000008566 Pinus taeda Nutrition 0.000 claims description 4
- 235000006485 Platanus occidentalis Nutrition 0.000 claims description 4
- 241000219492 Quercus Species 0.000 claims description 4
- 235000009137 Quercus alba Nutrition 0.000 claims description 4
- 244000274906 Quercus alba Species 0.000 claims description 4
- 235000009135 Quercus rubra Nutrition 0.000 claims description 4
- 240000004885 Quercus rubra Species 0.000 claims description 4
- 244000004774 Sabina virginiana Species 0.000 claims description 4
- 241000533293 Sesbania emerus Species 0.000 claims description 4
- 240000002871 Tectona grandis Species 0.000 claims description 4
- 235000000587 Tieghemella heckelii Nutrition 0.000 claims description 4
- 240000007662 Tieghemella heckelii Species 0.000 claims description 4
- 235000001856 mountain paper birch Nutrition 0.000 claims description 4
- 235000001842 paper birch Nutrition 0.000 claims description 4
- 235000001520 savin Nutrition 0.000 claims description 4
- 229920001807 Urea-formaldehyde Polymers 0.000 claims description 3
- SLGWESQGEUXWJQ-UHFFFAOYSA-N formaldehyde;phenol Chemical compound O=C.OC1=CC=CC=C1 SLGWESQGEUXWJQ-UHFFFAOYSA-N 0.000 claims description 3
- 239000012948 isocyanate Substances 0.000 claims description 3
- 150000002513 isocyanates Chemical class 0.000 claims description 3
- 229920001568 phenolic resin Polymers 0.000 claims description 3
- ODGAOXROABLFNM-UHFFFAOYSA-N polynoxylin Chemical compound O=C.NC(N)=O ODGAOXROABLFNM-UHFFFAOYSA-N 0.000 claims description 3
- 241000219495 Betulaceae Species 0.000 claims description 2
- 241001655736 Catalpa bignonioides Species 0.000 claims description 2
- 240000008444 Celtis occidentalis Species 0.000 claims description 2
- 235000018962 Celtis occidentalis Nutrition 0.000 claims description 2
- 239000004372 Polyvinyl alcohol Substances 0.000 claims description 2
- 239000004820 Pressure-sensitive adhesive Substances 0.000 claims description 2
- 239000000835 fiber Substances 0.000 claims description 2
- 239000011159 matrix material Substances 0.000 claims description 2
- 229920002451 polyvinyl alcohol Polymers 0.000 claims description 2
- 238000009408 flooring Methods 0.000 description 50
- 238000000034 method Methods 0.000 description 9
- 238000007906 compression Methods 0.000 description 7
- 230000006835 compression Effects 0.000 description 6
- 230000008859 change Effects 0.000 description 5
- 238000005562 fading Methods 0.000 description 5
- 238000009434 installation Methods 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 5
- 239000010876 untreated wood Substances 0.000 description 5
- 239000011121 hardwood Substances 0.000 description 4
- 230000008569 process Effects 0.000 description 4
- 239000007787 solid Substances 0.000 description 4
- 235000010328 Acer nigrum Nutrition 0.000 description 3
- 235000010157 Acer saccharum subsp saccharum Nutrition 0.000 description 3
- 230000000052 comparative effect Effects 0.000 description 3
- 238000010276 construction Methods 0.000 description 3
- 238000000926 separation method Methods 0.000 description 3
- 238000001179 sorption measurement Methods 0.000 description 3
- 241001123297 Acer saccharum subsp. saccharum Species 0.000 description 2
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 230000008602 contraction Effects 0.000 description 2
- 230000002349 favourable effect Effects 0.000 description 2
- 238000005470 impregnation Methods 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 239000011120 plywood Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 230000008961 swelling Effects 0.000 description 2
- 238000011282 treatment Methods 0.000 description 2
- 244000205124 Acer nigrum Species 0.000 description 1
- QTBSBXVTEAMEQO-UHFFFAOYSA-M Acetate Chemical compound CC([O-])=O QTBSBXVTEAMEQO-UHFFFAOYSA-M 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 1
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- 235000013264 Pinus jeffreyi Nutrition 0.000 description 1
- 235000016013 Pinus leiophylla var chihuahuana Nutrition 0.000 description 1
- 229920002472 Starch Polymers 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 238000000137 annealing Methods 0.000 description 1
- 229920013724 bio-based polymer Polymers 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000007767 bonding agent Substances 0.000 description 1
- DQXBYHZEEUGOBF-UHFFFAOYSA-N but-3-enoic acid;ethene Chemical compound C=C.OC(=O)CC=C DQXBYHZEEUGOBF-UHFFFAOYSA-N 0.000 description 1
- 239000004568 cement Substances 0.000 description 1
- 239000011093 chipboard Substances 0.000 description 1
- 239000004567 concrete Substances 0.000 description 1
- 230000001143 conditioned effect Effects 0.000 description 1
- 239000007799 cork Substances 0.000 description 1
- 230000001186 cumulative effect Effects 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000000280 densification Methods 0.000 description 1
- 230000000994 depressogenic effect Effects 0.000 description 1
- 238000003795 desorption Methods 0.000 description 1
- 239000013536 elastomeric material Substances 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 239000005038 ethylene vinyl acetate Substances 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 239000005357 flat glass Substances 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 239000003112 inhibitor Substances 0.000 description 1
- 235000013490 limbo Nutrition 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 239000003209 petroleum derivative Substances 0.000 description 1
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 238000005067 remediation Methods 0.000 description 1
- 230000001932 seasonal effect Effects 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 241000894007 species Species 0.000 description 1
- 239000008107 starch Substances 0.000 description 1
- 235000019698 starch Nutrition 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000004381 surface treatment Methods 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- 229910052724 xenon Inorganic materials 0.000 description 1
- FHNFHKCVQCLJFQ-UHFFFAOYSA-N xenon atom Chemical compound [Xe] FHNFHKCVQCLJFQ-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/04—Flooring or floor layers composed of a number of similar elements only of wood or with a top layer of wood, e.g. with wooden or metal connecting members
- E04F15/041—Flooring or floor layers composed of a number of similar elements only of wood or with a top layer of wood, e.g. with wooden or metal connecting members with a top layer of wood in combination with a lower layer of other material
- E04F15/042—Flooring or floor layers composed of a number of similar elements only of wood or with a top layer of wood, e.g. with wooden or metal connecting members with a top layer of wood in combination with a lower layer of other material the lower layer being of fibrous or chipped material, e.g. bonded with synthetic resins
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27M—WORKING OF WOOD NOT PROVIDED FOR IN SUBCLASSES B27B - B27L; MANUFACTURE OF SPECIFIC WOODEN ARTICLES
- B27M1/00—Working of wood not provided for in subclasses B27B - B27L, e.g. by stretching
- B27M1/02—Working of wood not provided for in subclasses B27B - B27L, e.g. by stretching by compressing
-
- 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
- B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
- B32B21/10—Next to a fibrous or filamentary 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
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
- B32B3/06—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers together; for attaching the product to another member, e.g. to a support, or to another product, e.g. groove/tongue, interlocking
-
- 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
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
-
- 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
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/06—Vegetal fibres
- B32B2262/062—Cellulose fibres, e.g. cotton
-
- 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
- B32B2307/51—Elastic
-
- 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
- B32B2307/558—Impact strength, toughness
-
- 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
- B32B2471/00—Floor coverings
Definitions
- the present invention is directed to a treated cellulosic material. More specifically, the present invention is directed to flooring having a densified cellulosic subtrate.
- Wood flooring endures seasonal expansion and contraction when exposed to variations in equilibrium moisture content (EMC). When EMC levels plummet, boards shrink, creating spaces between the wood flooring boards. During periods of both elevated EMC and depressed EMC, installed wood flooring boards change dimension creating cupping (moisture adsorption from the bottom of the product), a condition in which the edges of the board are high and the center is low; or crowning (moisture adsorption from the top or face of the product), the opposite of cupping, where the middle of the board is higher than the edges of the board.
- cupping moisture adsorption from the bottom of the product
- crowning moisture adsorption from the top or face of the product
- Engineered wood flooring is a multiple-layered structure having a top layer of decorative wood veneer bonded to multiple core or base layers of a manufactured wood product, for example, fiberboard and veneer core plywood.
- Engineered wood floors have a greater resistance to dimensional change in elevated EMC conditions than solid wood flooring and appeal to use in below grade and in regions of high EMC. In the case of dry EMC conditions however, dimensional changes in engineered wood flooring lead to in-service issues.
- Engineered wood flooring made with rotary-peeled face veneers tends to exhibit veneer checking or lathe checks, a condition that creates micro cracks in the decorative wood veneer layer of the product.
- a wood flooring product that is dimensionally stable to variations in EMC, resists veneer checks, indent resistant, and resists fading from exposure to sunlight would be desirable in the art.
- Some embodiments of the present invention provide a hybrid wood product, comprising: a first layer comprising a first thermally compressed cellulosic substrate; a second layer comprising a fiberboard, a wood-plastic composite, or a vinyl composite; and a locking profile.
- a densified wood product having a first layer and a second layer wherein the first layer is a densified wood veneer and the second layer is bonded to the first layer.
- thermal compression refers to products or processes that use - inter alia - heat and mechanical compression to densify a substrate.
- Exemplary thermal compression techniques are described in U.S. Patent No. 7,404,422 to Kamke et al., the contents of which are hereby incorporated herein in their entirety.
- the compression process comprises the following steps: providing an apparatus comprising: a top calendar roll; a bottom calendar roll; a heat source; and an in-feed conveyor; wherein the distance between the top calendar roll and the bottom calendar roll defines a separation gap; providing a cellulosic substrate having a thickness greater than the separation gap; and feeding the cellulosic substrate through the separation gap between the top calendar roll and the bottom calendar roll.
- Some embodiments of the present invention provide a hybrid wood product, comprising: a first layer comprising a first thermally compressed cellulosic substrate; a second layer comprising a fiberboard, a wood-plastic composite, or a vinyl composite; and a locking profile.
- the first thermally compressed cellulosic substrate comprises a cellulosic material derived from a soft wood or a tropical wood.
- the first thermally compressed cellulosic substrate comprises a cellulosic material derived from Caribbean walnut, coffee bean, natural bamboo, Australian cypress, white oak, Kenyan oak, ribbon gum, ash, American beech, red oak, Caribbean heart pine, yellow birch, Movingui, heart pine, Carapa Guianensis, larch, carbonized bamboo, teak, cocobolo, rose gum, Makore, Siberian larch, Peruvian walnut, Boreal, black walnut, cherry, red maple, boire, paper birch, eastern red cedar, southern yellow pine, lacewood, African mahogany, Honduran mahogany, Parana, sycamore, Shedua, silver maple, Douglas fir, juniper, chestnut, hemlock, western white pine, basswood, eastern white pine, balsa
- the first thermally compressed cellulosic substrate comprises a cellulosic material derived from eastern white pine, hemlock, catalpa, alder, cypress, Douglas fir, hackberry, cherry or a combination thereof.
- the second layer comprises a fiberboard.
- the fiberboard comprises a matrix of cellulosic fibers.
- the fiberboard further comprises a binder.
- the binder comprises a formaldehyde based resin, isocyanate, polyvinyl alcohol, soy, or a combination of two or more thereof.
- the formaldehyde based resin is selected from urea formaldehyde; phenol formaldehyde; and a combination thereof.
- the fiberboard has a moisture content of less than 9%. In some embodiments, the fiberboard has a moisture content of less than 8%. In some embodiments, the fiberboard has a moisture content of less than 7%. In some embodiments, the fiberboard has a moisture content of less than 6%. In some embodiments, the fiberboard has a moisture content of less than 5%.
- the fiberboard has a density of from about 10 lbs./ft to about 75
- the fiberboard has a density of from about 15 lbs./ft to about 70
- the fiberboard has a density of from about 20 lbs./ft to about 65
- the fiberboard has a density of from about 25 lbs./ft to about 50 lbs./ft 3 .
- the fiberboard has a thickness of from about 3 mm to about 14 mm. In some embodiments, the fiberboard has a thickness of from about 4 mm to about 12 mm. In some embodiments, the fiberboard has a thickness of from about 5 mm to about 10 mm.
- the second layer has a modulus of elasticity of from about 30,000 psi to about 1,000,000 psi. Some embodiments provide a second layer having a modulus of elasticity of from about 40,000 psi to about 900,000 psi. Other embodiments provide a second layer having a modulus of elasticity of from about 50,000 psi to about 500,000 psi.
- the second layer is bonded to the first layer using an adhesive.
- the hybrid product comprises a locking profile is selected from tongue and groove; lock and fold; ship-lap; angle-angle; and click-lock.
- the locking profile is selected from tongue and groove and lock and fold. Suitable locking profiles are described, for example, in U.S. Patent No. 8,544,234 to Pervan et al. or U.S. Patent No. 6,874,292 to Moriau et al., the contents of which are hereby incorporated herein in their entireties.
- the second layer comprises the locking profile.
- the adhesive comprises a pressure sensitive adhesive. In some embodiments, the adhesive comprises a heat sensitive adhesive, e.g. ethylene vinyl acetate. [0026] In some embodiments, the hybrid product has a thickness of from about 6 mm to about 12 mm. In some embodiments, the hybrid product has a width of from about 75 mm to about 200 mm.
- Some embodiments provide a product comprising a third layer.
- the third layer comprises a second thermally compressed cellulosic substrate.
- the second thermally compressed cellulosic substrate comprises a cellulosic material derived from a soft wood or a tropical wood. In some embodiments, the second thermally compressed cellulosic substrate comprises a cellulosic material derived from
- the first thermally compressed cellulosic substrate and the second thermally compressed cellulosic substrate are comprised of the same material.
- Some embodiments of the present disclosure permit the manufacture of densified wood products and materials that are indent resistant, dimensionally stable from variations in equilibrium moisture content, and resistant to fading. Some embodiments are further processed by cutting and shaping to include flooring and underlayment materials, trim, and furniture manufacture.
- a veneer is a thin sheet of wood, rotary cut, sliced, or sawed from a log, bolt, or flitch.
- the formation of densified wood and densified veneer products would permit the manufacture of, for example, wood flooring having densified wood or veneer in the core construction or as decorative layer.
- Veneer checks usually appear as uniformly spaced hairline cracks in the finish, or in severe cases, cracks with accompanying ridges on the wood surface which actually can be detected by touch. Veneer checks are typically formed when tensile stress failures occur in the face veneer, caused by differential shrinkage or swelling between the face veneer and the panel substrate to which it is applied. As the EMC of the environment changes, so does the moisture content of the wood panel. Changes in moisture content of the wood panel affect shrinkage and swelling of the wood panel.
- veneer checks formed from the veneer process were compressed and closed after densifying the wood veneer, and, therefore, engineered wood flooring made with densified rotary-peeled face veneers are suitable for installations having dry environmental conditions.
- the wood flooring product includes multiple layers. Although two layers are detailed herein, the wood flooring product includes about three layers, about four layers, about five layers, about six layers, about seven layers, about eight layers, about nine layers, about ten layers, about eleven layers, or additional layers as warranted by the product construction.
- a densified wood or veneer is positioned as a top or decorative layer in a multi-layer wood flooring product.
- the densified wood or veneer forms the base of a layered wood flooring product.
- the densified wood is positioned throughout a layered wood flooring product to improve the dimensional stability of the layered wood flooring product.
- the top layer also referred to as a first layer or decorative layer, includes a densified veneer.
- the top layer is bonded to one or more layers by epoxy, urethane, acrylate, acetate, phenol formaldehyde, urea formaldehyde, isocyanate, soy, starch, or protein- based, or other biobased adhesives, or any other bonding agent as known in the arts.
- the base layer is solid wood such as a hard wood, a soft wood, or a porous material such as cork.
- the densified top layer is bonded to one or more layers where the base layer is a manufactured cellulosic product, for example medium density fiberboard, high density fiberboard, plywood, oriented strand board, chipboard, felt, or any other suitable product.
- the densified top layer is bonded to one or more layers where the base layer is cement, concrete, or composites thereof.
- the base layer contains a polymeric binder, for example, but not limited to, extruded wood products, filled polymeric compositions, urethane foams, or any other suitable material.
- the polymeric binder of the base layer is an acrylated, epoxidized, or esterified biobased polymer such that the polymer components are derived from natural, renewable sources as opposed to petroleum products. Additionally or alternatively, filled polymeric compositions have fillers obtained from natural, renewable sources, such as, aragonite. Additionally, the base layer could be a rubber- based, elastomeric-based material or a wood plastic composite type of material which is a combination of cellulosic with polymeric or filled polymeric or elastomeric material.
- Densified wood is prepared by several methods, for example, by injecting a resin such as phenol, into the wood to strengthen the wood by the curing of the resin. Wood may also be densified by a combination of injecting resins and compressing the wood. Other methods include a process whereby the wood is subjected to an elevated temperature and moisture, compressing the wood component perpendicular to the grain, and annealing the wood to ambient conditions.
- a resin such as phenol
- the densification of wood increased the density to about 1.30 times or greater of the initial density of the wood.
- the densified wood product having a densified veneer is obtained from species of hard wood, soft wood, or tropical wood.
- a densified wood product having a densified veneer is fashioned into planks, having an edge perpendicular to the face and any combination of thickness, width, and length as required.
- the densified wood product having a densified veneer is fashioned into planks, having any combination of thickness, width, and length as required and the elongated edges machined to include a tongue and groove feature.
- the densified wood product having a densified veneer is fashioned into planks, having any combination of thickness, width and length as required and the elongated edges further machined to have locking tongue and groove features.
- a wood flooring product having dimensions of thickness, width and length vary to suit the application. Thickness varies from about 1/16 inch to about 1 inch, from about 1/16 inch to about 1/4 inch, from about 1/4 inch to about 3/8 inch, from about 5/16 inch to about 1/2 inch, from about 5/8 inch to about 7/16 inch, from 3/4 inch to about 1 inch, or any size in between.
- Flooring width varies from about 2 inches to about 24 inches, from about 2 inches to about 3-1/4 inches, from about 3-1/4 inches to about 5 inches, and from about 5 inches to about to 12 inches, from about 12 inches to about 16 inches, from about 12 inches to about 24 inches, or any size in between.
- Lengths are, for example, but not limited to, about one-half foot to about twelve feet, from about one-half foot to about one foot, from about three feet to about six feet, from about eight feet to about ten feet, from about ten feet to about twelve feet, from about one- half meter to about one meter, from about two meters to about three meters and from about three meters to about four meters, or any size in between.
- the flooring is a square tile having equal dimensions of two adjacent sides from about 2 inches to about 24 inches, from about 2 inches to about 2 inches, from about 4 inches to about 4 inches, from about 6 inches to about 6 inches, from about 9 inches to about 9 inches, from about 12 inches to about 12 inches, from about 16 inches to about 16 inches, from about 18 inches to about 18 inches, from about 24 inches to about 24 inches, or any size in between.
- Wood flooring products are subjected to impacts from objects that may be inadvertently dropped onto flooring surfaces. It is not possible to know all of the factors related to the dropped objects (shape, weight, height of drop) or the condition of the environment in which the floor is located (types of sub floor, degree of adhesion to sub floor, temperature). Wood floor specimens having a densified first layer are evaluated for impact resistance using a ball drop test method which provides a relative measure of resistance to impact of wood flooring. In one embodiment, the wood flooring product having densified first layer has an indent resistance greater than untreated wood.
- Width and thickness dimensions of wood flooring typically change when wood flooring is exposed to variations in EMC. Wood flooring maintains dimensional stability in the ambient relative humidity range between about 30 percent to about 50 percent. Humid conditions occur when the ambient relative humidity is above 50 percent, above 60 percent, above 70 percent, and above 80 percent. Conversely, dry conditions occur when the ambient relative humidity is less than 30 percent, less than 20 percent, and less than 10 percent. In moist conditions, moisture adsorption causes wood flooring boards to expand across the width of the boards. Conversely, in dry conditions, moisture desorption causes wood flooring boards to contract across the width of the boards. In both moist and dry conditions, the cumulative effects of expansion and contraction result in cupping and crowning across wood flooring boards.
- the potential to cup or crown is a limitation for use of wood flooring in below grade or other installations which typically have wet or moist conditions as well as dry conditions and is further exacerbated when wider width wood flooring, for example, greater than 3.25 inches wide, is installed.
- the densified wood product having a densified veneer has greater resistance to dimensional changes due to EMC changes than untreated wood.
- the wood flooring product having a densified veneer is dimensionally stable as associated with wet and dry conditions and, therefore, is suitable for installations below grade or having moist conditions as well as dry conditions.
- a wood flooring product having a densified veneer has a width greater than 3.25 inches.
- Wood flooring products especially solid wood and veneer, fade or change shades over time. Exposure to sunlight greatly exacerbates this problem. Methods in the art to slow the fading process include treatments, for example, a surface treatment containing ultraviolet inhibitors that add additional cost to the manufactured product and further hinder refinishing techniques. In one embodiment, wood flooring products having a densified first layer without additional treatments have favorable light stability as compared to untreated wood.
- Impact resistance is conducted where a 1-1/2 inch diameter steel ball, supported in a housing, is dropped from a predetermined height and the impact depth, if any, in the surface of the flooring product is measured at its greatest depth. A smaller depth or penetration denotes a greater impact resistance.
- First layers comprising an exemplary hard wood (hard maple) and an exemplary soft wood (yellow pine) were evaluated to understand the influence of thermal compression on impact resistance. As shown in Table 1, the influence of thermal compression on a hard wood is minimal. In contrast, Table 2 illustrates that the influence of thermal compression on soft wood is significant. Specifically, the data described in Table 2 demonstrates that exemplary products of the present invention demonstrate an unexpected improvement in impact resistance.
- Thermally compressed and untreated samples are evaluated for color difference based on the calculation of delta values as the deviation of the measured x, y color coordinates from a black body radiator.
- Test duration affords exposure to 100 hours of xenon arc, having 280 nm - 800 nm wavelength, and filtered to approximate sunlight through window glass.
- results are the differential from the initial color reading to the final color reading. Less of a difference is favorable, as shown in Table 3, a wood product having a thermally compressed first layer has a greater resistance to fading than untreated wood.
- Moisture resistance is evaluated where specimens of untreated and densified wood are conditioned to yield an equilibrium moisture content of approximately 4 percent. Initial specimen weights are recorded. Test specimens are subjected to 79 percent relative humidity, at 25° C, (approximately fifteen percent EMC) for nine days. At the conclusion of the test, specimens are weighed and the percent of moisture gain reported. As shown in Table 3, densified wood has a lower moisture uptake than untreated wood.
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- Life Sciences & Earth Sciences (AREA)
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Abstract
Description
Claims
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US201361806702P | 2013-03-29 | 2013-03-29 | |
PCT/US2014/032174 WO2014160938A1 (en) | 2013-03-29 | 2014-03-28 | Hybrid wood products |
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EP2978910A1 true EP2978910A1 (en) | 2016-02-03 |
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EP14722915.7A Withdrawn EP2978910A1 (en) | 2013-03-29 | 2014-03-28 | Hybrid wood products |
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EP (1) | EP2978910A1 (en) |
CN (1) | CN105102738A (en) |
AU (1) | AU2014240948B2 (en) |
WO (1) | WO2014160938A1 (en) |
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Publication number | Priority date | Publication date | Assignee | Title |
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US10576715B2 (en) | 2015-07-10 | 2020-03-03 | Aladdin Manufacturing Corporation | Flooring board with a thin veneer wood aesthetic and durable surface |
CN107150382A (en) * | 2017-01-11 | 2017-09-12 | 廖伟登 | The laminate for building that pine and cypress eucalyptus is mixed |
CN112118942B (en) * | 2017-12-29 | 2023-04-07 | Ahf有限责任公司 | Densified wood and process of making |
FR3077895B1 (en) * | 2018-02-09 | 2020-02-28 | Sas Woodoo | TACTILE DETECTION DEVICE WITH TACTILE INTERFACE IN COMPOSITE MATERIAL |
CN108568877A (en) * | 2018-04-23 | 2018-09-25 | 安吉席丫丫竹木有限公司 | A kind of bamboo sofening treatment technique |
CN109732936A (en) * | 2018-12-29 | 2019-05-10 | 广州高朗环保科技有限公司 | A kind of preparation process of enhanced Wood model compound products |
CN110819131A (en) * | 2019-11-20 | 2020-02-21 | 东莞市顶好手袋皮具有限公司 | Coffee grounds cork cloth and manufacturing method thereof |
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US3636199A (en) * | 1969-02-04 | 1972-01-18 | Allied Chem | Synthetic board inlaid with moisture-cure urethane and method therefor |
CN2076142U (en) * | 1989-05-23 | 1991-05-01 | 陈光华 | Composite cork parquet floor |
US5618602A (en) * | 1995-03-22 | 1997-04-08 | Wilsonart Int Inc | Articles with tongue and groove joint and method of making such a joint |
SE515789C2 (en) * | 1999-02-10 | 2001-10-08 | Perstorp Flooring Ab | Floor covering material comprising floor elements which are intended to be joined vertically |
DE19925867A1 (en) * | 1999-06-07 | 2000-12-14 | Hamberger Industriewerke Gmbh | Connecting system for force or form locking connection of at least two floorboard panels has locking recess in lower face of locking groove lying outside plane of vertical end face having groove |
FR2846687B1 (en) * | 2002-10-30 | 2004-12-31 | Tarkett Sommer Sa | MOISTURE TREATED SURFACE COATING AND PROCESSING METHOD |
US7404422B2 (en) * | 2003-02-05 | 2008-07-29 | Eagle Analytical Company, Inc. | Viscoelastic thermal compression of wood |
SE530520C2 (en) * | 2006-01-12 | 2008-06-24 | Vaelinge Innovation Ab | Laminate Panels |
CN100392201C (en) * | 2006-08-22 | 2008-06-04 | 浙江林学院 | Solid wood composite floor fit for geothermal heat and manufacturing method thereof |
KR100970112B1 (en) * | 2006-09-26 | 2010-07-15 | (주)엘지하우시스 | Wood flooring with carbonized solid wood using symmetric structure and process for preparing the same |
-
2014
- 2014-03-28 CN CN201480019928.2A patent/CN105102738A/en active Pending
- 2014-03-28 WO PCT/US2014/032174 patent/WO2014160938A1/en active Application Filing
- 2014-03-28 AU AU2014240948A patent/AU2014240948B2/en not_active Ceased
- 2014-03-28 EP EP14722915.7A patent/EP2978910A1/en not_active Withdrawn
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Also Published As
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CN105102738A (en) | 2015-11-25 |
AU2014240948B2 (en) | 2016-10-20 |
WO2014160938A1 (en) | 2014-10-02 |
AU2014240948A1 (en) | 2015-10-15 |
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