US3230287A - Process for manufacturing moldable fibrous panels - Google Patents

Process for manufacturing moldable fibrous panels Download PDF

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Publication number
US3230287A
US3230287A US226490A US22649062A US3230287A US 3230287 A US3230287 A US 3230287A US 226490 A US226490 A US 226490A US 22649062 A US22649062 A US 22649062A US 3230287 A US3230287 A US 3230287A
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United States
Prior art keywords
mat
density
pounds per
range
uniform
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Expired - Lifetime
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US226490A
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English (en)
Inventor
Philip E Caron
Gene A Grove
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Weyerhaeuser Co
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Weyerhaeuser Co
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Publication date
Application filed by Weyerhaeuser Co filed Critical Weyerhaeuser Co
Priority to US226490A priority Critical patent/US3230287A/en
Priority to SE9455/63A priority patent/SE305313B/xx
Priority to DEW35207A priority patent/DE1224919B/de
Priority to GB37940/63A priority patent/GB999445A/en
Application granted granted Critical
Publication of US3230287A publication Critical patent/US3230287A/en
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    • 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
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21J—FIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
    • D21J1/00—Fibreboard

Definitions

  • the present invention relates to the production of a self-supporting mat comprising fibers and binder material which can be compressed, shaped or formed to a permanent, rigid predetermined contoured article.
  • moldable preforms of fiber binder composition have been made by a continuous process of air-laying the fibers and binder composition to form a felt upon a foraminous screen.
  • the low density mat (1 to 3 pounds per cubic foot) is then pre-pressed to condense the mat to a density wherein it is handleable and transportable upon a caul.
  • the mats are then individually handled and stacked until ready for entry into a multiple opening fiat platen press for consolidation to a self-supporting mat structure.
  • the present invention avoids the above described combination of continuous and batch handling. It permits the practice of a continuous process from air-laying of fiber to emergence of a self-supporting fiber panel. Thus, the provision and the handling of cauls is eliminated. The costly platen hot press and the handling required therefore is eliminated, as Well as other incidental labor and equipment used as a result of platen-pressing.
  • the present invention permits a much greater production rate than the platen-pressing system with an appreicable reduction in capital expenditures. It permits of a more controllable system and thus a more uniform product.
  • a further object of this invention is the provision of a continuous process for forming moldable fibrous mats having both uniform density and uniform thickness.
  • An additional object of this invention is the provision of a continuous process for the formation of a low-density fibrous mat having a binder therein and the transformation of this mat to a moldable fibrous mat having uniform density and uniform thickness.
  • a mat comprising fiber and binder is formed by pneumatic deposition on a foraminous conveyor, or wire screen, such as is commonly used in some continuous air-laying processes.
  • a foraminous conveyor, or wire screen such as is commonly used in some continuous air-laying processes.
  • Such deposited mats frequently have an irregular surface, which if the mat is consolidated to a uniform thickness will result in non-uniform density.
  • a scalping station where one or more scalping rolls remove the top layer of the mat to form a level felted mat of uniform thickness and density.
  • the leveled mat and its conveyor may then be passed through one or more sets of compression rolls to initially reduce the original thickness and increase the original felted density to a range of 4 to pounds per cubic foot.
  • the mat and its conveyor next are passed through a conditioning stage which quickly raises the temperature of the mat to a temperature in the range of 90 F. to 200 F. preferably in the range of F. to F.
  • the conditioning stage comprises chambers opening close to the two faces of the mat, which chambers contain a heating gaseous fluid such as steam or hot air.
  • the moisture content of the heated mat leaving the heating stage is important as Well as the temperature and should be within the range of 8l5%. Sufiicient moisture in combination with heat is required to adequately plasticize the fibers for effective consolidation but not so great as to cause subsequent sticking to the compression rolls resulting in soft or fuzzy surface panels.
  • the time of exposure is important so as not to dry out the surfaces, or set up thermosetting resins when present, while attaining the internal temperature and moisture content desired.
  • the mat should be sufficiently open and porous for the heating fiuid readily to diffuse into it in a very short period of time, such as in the range of from 2 to 20 seconds. It is also preferred that the heating gaseous fluid be applied from both sides of the mat to minimize any tendency of the finished cut panels to be unbalanced or to bow.
  • a mat so heated internally and with a moisture content of 8% to 15% may be immediately cold roll pressed at pressures of from 100 to 500 pounds per lineal inch to a density in the range from 30 to 60 pounds per cubic foot, and on removal of the compression force, substantially retain that density.
  • this invention permits the manufacture of a continuous self-supporting moldable fibrous panel structure by a continuous process including in a series the steps of pneumatic deposition, initial light compression, treatment by hot gaseous fluid, and cold rolling compression, followed by uncompressed cooling.
  • the fiber is preferably wood fiber, although other fibers both organic and inorganic may be combined therewith.
  • the resin may be thermoplastic or thermosetting or a combination of the same.
  • the composition of the board with respect to fiber and the types of resin may vary greatly. Typical resins that may be used are phenolformaldehyde resin, wood rosin, polyvinyl acetate, paraffin, and neoprene. From 1 to 30%, on an oven dry solids basis, of these resins either singly or in combination may be mixed with the fibers.
  • thermoplastic resin and the thermosetting resin may be incorporated with the fibers by introducing the resins into the stream of fiber and steam which emerges from the defibrator, as described in the following Heritage US. Patents: Nos. 2,940,134; 2,757,115; 2,757,148; 2,757,149; and 2,757,150 (which also disclose pneumatic deposition of fibers).
  • the fiber is conducted rapidly in conduits and in transit is reduced in its moisture content to a desired level.
  • a moisture content in the range from 8% to 18% (oven dry basis) is desired for felting the fiber, and it has been found that in the range from 11% to 14% (oven dry basis) the roll pressure required for the final compression is the least.
  • a resulting level felt 16 having a low density of approximately 2 pounds per cu. ft. is compressed by a pair of rolls 17 and 18 to a density of 4 to 10 pounds per cu. ft.
  • the compressed Web 20 moving at up to 100 feet per minute passes through a steam environment, which effects an adequate steaming.
  • the steam environment is shown as provided by steam chambers having perforated plate faces spaced apart to permit the conveyor 14 and mat 20 to pass through with a of clearance.
  • chamber 22 over the top of mat 20 receives steam by inlet 24, and it is positioned within an exhaust hood 216 which extends in both directions away from the chamber 22 in the direction of travel of the web.
  • Chamber 28 receives steam at inlet 30 and opens immediately adjacent the underside of conveyor 14. It is understood that chamber 22 and exhaust hood 26 may be so constructed that they can be raised or lowered to accommodate various mat heights.
  • the web then immediately enters a pair of unheated press rolls, designated 32 and 34.
  • These are large in diameter to receive a thick mat and to effect a large decrease in its thickness.
  • steel rolls 24 inches in diameter will receive a mat 7 inches thick with a density of 4 to 10 pounds per cu. ft. and reduce it to a thickness in the range from i to 1 inch.
  • the final moldable panel. of desired density is easily obtainable by setting the rolls at a fixed thickness nip and applying sufiicient pressure to maintain that setting.
  • the pressure required at the final roll pressing may vary from 100 to 500 pounds per lineal inch.
  • a minimum pressure of 100 pounds per lineal inch is required to substantially maintain the compressed density of the panel after leaving the rolls While a maximum pressure of 500 pounds per lineal inch avoids any tendency to disrupt the structure of the mat as originally felted. or to weaken the individual fibers which might result in faults in the finished molded article or even prevent the successful shaping of the final article due to fracturing while forming in matched dies.
  • the conveyor 14 is separated from the mat 20 just before the mat enters the unheated press rolls, as shown by the return idler rolls designated 36-3738.
  • the compressed mat 40 from the press rolls ridesv onto a coarse-mesh endless screen conveyor 42 for carrying the mat through drying and cooling stations when it is desired to hasten the reduction of moisture content to or toward equilibrium with the atmosphere.
  • the compressed mat 40 passes over a suction box 44 connected to a suction fan 46, opposite a heated air chamber 48 above the mat 40.
  • a steam coil 50 in the chamber heats air drawn from the atmosphere. by fan 46 through the mat 40.
  • thermosetting resin In order to hasten the cooling of the compressed mat 40 to or toward normal temperature a second suction box 52 connected to suction fan 54 draws atmospheric "in hot platen pressing to produce similar panels, surface densities are higher than internal densities frequently appearing as surface skins due to the longer exposure of the surface to the heat of the platens. Also, where ;part of the binder is thermosetting resin, it is difficult to control the platen-pressing to achieve the desired heating and compression and not at the same time partially react the thermosetting resin.
  • Production control figures sharply point this out wherein moldable fiber panels made by prior procedures using a platen press resulted in panels having a thickness deviation of as much as 11.8% within a panel With the most uniform panels having a thickness deviation of 9.3% with the panel.
  • the panels produced by the process of this invention have a thickness deviation of less than .025 within a single panel and from panel to panel.
  • Non-uniform areas of density and thickness associated with moldable panels of prior methods are accentuated .
  • the moldable panels produced by the process herein described easily can be further processed by shaping or forming in matched metal dies to provide densified rigid articles for commercial applications, such as tote boxes, luggage shells, contoured door panels for automobiles, and contoured chair bodies.
  • the process of the present invention not only provides a moldable panel of uniform density, thickness and structure, but provides successive panels of the same controllable consistent uniformity of structure and content from face to face.
  • the method of forming a moldable rigid felted fiber panel of uniform density, thickness and structure which comprises continuously pneumatically depositing and felting on a moving foraminous conveyor the solid contents of an air-suspension comprising feltable fibers and a resinous binder and thereby forming a mat having a density in the range from 1 to 3 pounds per cubic foot; removing the non-uniform top surface of the mat, pressing the remainder of said mat to a density in the range of 4 to 10 pounds per cubic foot, conditioning said pressed mat by subjecting the two faces of the mat to a hot gaseous environment for a time suflicient to adjust the moisture content in the range of from 8-15 and the internal temperature in the range of F.
  • the resinous binder comprises a mixture of thermosetting and thermoplastic resin.

Landscapes

  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Wood Science & Technology (AREA)
  • Forests & Forestry (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)
  • Nonwoven Fabrics (AREA)
US226490A 1962-09-27 1962-09-27 Process for manufacturing moldable fibrous panels Expired - Lifetime US3230287A (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
US226490A US3230287A (en) 1962-09-27 1962-09-27 Process for manufacturing moldable fibrous panels
SE9455/63A SE305313B (cs) 1962-09-27 1963-08-29
DEW35207A DE1224919B (de) 1962-09-27 1963-09-02 Verfahren und Vorrichtung zum Herstellen von pressbaren Faserplatten
GB37940/63A GB999445A (en) 1962-09-27 1963-09-26 Process for manufacturing moldable fibrous panels

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US226490A US3230287A (en) 1962-09-27 1962-09-27 Process for manufacturing moldable fibrous panels

Publications (1)

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US3230287A true US3230287A (en) 1966-01-18

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US226490A Expired - Lifetime US3230287A (en) 1962-09-27 1962-09-27 Process for manufacturing moldable fibrous panels

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US (1) US3230287A (cs)
DE (1) DE1224919B (cs)
GB (1) GB999445A (cs)
SE (1) SE305313B (cs)

Cited By (30)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3304356A (en) * 1964-04-18 1967-02-14 Kralinator Filters Ltd Method of producing plastic fiber filters
US3313002A (en) * 1965-08-04 1967-04-11 Du Pont Apparatus for heat treating sheet material
US3377220A (en) * 1967-06-09 1968-04-09 American Filtrona Corp Process for making stable elongated elements
US3679790A (en) * 1966-12-12 1972-07-25 Alf Adolf Alfsen Method of finishing boards of vegetable material
US3709651A (en) * 1970-09-08 1973-01-09 Saint Gobain Apparatus for the production of shaped articles of expanded cohered granules of thermoplastic material, in particular polystyrene
US3850558A (en) * 1972-02-15 1974-11-26 Bordon Chem Co Installation for manufacturing resin based concrete
US3969459A (en) * 1973-07-18 1976-07-13 Champion International Corporation Fiberboard manufacture
US3973893A (en) * 1973-04-26 1976-08-10 Southampton Manufacturing Company, Inc. Apparatus for continuously manufacturing boards
US3975483A (en) * 1967-01-12 1976-08-17 Bernard Rudloff Process for manufacturing stratified materials
US3992135A (en) * 1975-07-07 1976-11-16 Southampton Manufacturing Company, Incorporated Apparatus for continuously manufacturing boards
US4025272A (en) * 1975-07-07 1977-05-24 Southampton Manufacturing Company, Inc. Apparatus for continuously manufacturing boards
US4028457A (en) * 1973-04-16 1977-06-07 Domtar Limited Consolidation of dry formed webs
US4056342A (en) * 1973-07-18 1977-11-01 Champion International Corporation Fiberboard manufacture
US4086316A (en) * 1974-03-12 1978-04-25 Eduard Kusters Process for the manufacture of flat sheets or webs
US4096796A (en) * 1975-12-22 1978-06-27 Potlatch Corporation Apparatus and method for controlling press racking
US4216179A (en) * 1977-05-17 1980-08-05 Bison-Werke Bahre & Greten Gmbh & Co. Kg Process and an apparatus for the continuous manufacture of boards from material incorporating a heat hardenable binder
US4255108A (en) * 1979-01-19 1981-03-10 Morrison-Knudsen Forest Products Company, Inc. Furnish handling apparatus
US4293509A (en) * 1978-12-15 1981-10-06 Bison-Werke Bahre & Greten Gmbh & Co. Kg Process for the production of chipboards, fiberboards, or like boards
US4322380A (en) * 1979-01-19 1982-03-30 Morrison-Knudsen Forest Products Company, Inc. Method for feeding and orienting fibrous furnish
US4517147A (en) * 1984-02-03 1985-05-14 Weyerhaeuser Company Pressing process for composite wood panels
US4605467A (en) * 1984-03-29 1986-08-12 G. Siempelkamp Gmbh & Co. Apparatus for producing steam hardened pressedboard
US4626184A (en) * 1985-03-14 1986-12-02 Kimberly-Clark Corporation Scarfing apparatus
US4675144A (en) * 1985-03-14 1987-06-23 Kimberly-Clark Corporation Scarfing method
US5639411A (en) * 1994-12-21 1997-06-17 Holli-Nee Corporation Process for expanding glass fiber laminates and panels formed thereby
US5695848A (en) * 1994-12-21 1997-12-09 Nicofibers, Inc. Panel formed from molded fiberglass strands
US5762980A (en) * 1994-11-17 1998-06-09 Maschinenfabrik J. Dieffenbacher Gmbh & Co. Installation for the continuous production of boards of wood-based material
US6123884A (en) * 1995-04-07 2000-09-26 Valmet Fibertech Aktiebolag Method of manufacturing lignocellulosic board
US6136239A (en) * 1994-01-28 2000-10-24 Valmet Fibertech Aktiebolag Method of manufacturing lignocellulosic board
US20050058818A1 (en) * 2003-09-12 2005-03-17 West D. David Laminated composite and process of making same
CN102452182A (zh) * 2010-10-22 2012-05-16 上海宝钢化工有限公司 一种用于压实粉状原料的辊带压实机

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
SE424835B (sv) * 1978-07-07 1982-08-16 Ry Ab Maskin for att behandla lignocellulosahaltiga skivmaterial med gasformiga emnen
DE3009465C2 (de) * 1980-03-10 1985-09-19 Lignotock Verfahrenstechnik Gmbh, 1000 Berlin Schichtfasermatte zur Herstellung von räumlich verpreßten Formteilen im Trockenverfahren

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1881932A (en) * 1928-08-24 1932-10-11 Banner Rock Corp Process of forming self baking insulation blocks
US2480851A (en) * 1947-02-05 1949-09-06 Us Sheetwood Company Method for rapid manufacture of sheet lumber
US2493194A (en) * 1946-11-29 1950-01-03 Wood Conversion Co Manufacture of bonded fiber mats
US2544019A (en) * 1944-11-13 1951-03-06 Wood Conversion Co Manufacture of plastic-fiber composition
US2548095A (en) * 1948-01-10 1951-04-10 New England Box Company Production of construction materials from wood and other vegetable fibers
US2635301A (en) * 1948-09-30 1953-04-21 Plywood Res Foundation Web or mat forming device
US2744848A (en) * 1954-03-29 1956-05-08 Long Bell Lumber Company Making fiberboard of uniform density and thickness
US2757114A (en) * 1954-11-08 1956-07-31 Weyerhaeuser Timber Co Manufacture of glazed hardboard
US2925360A (en) * 1957-08-29 1960-02-16 Weyerhaeuser Co Method of preventing excessive springback of dry felted fiber mats

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1881932A (en) * 1928-08-24 1932-10-11 Banner Rock Corp Process of forming self baking insulation blocks
US2544019A (en) * 1944-11-13 1951-03-06 Wood Conversion Co Manufacture of plastic-fiber composition
US2493194A (en) * 1946-11-29 1950-01-03 Wood Conversion Co Manufacture of bonded fiber mats
US2480851A (en) * 1947-02-05 1949-09-06 Us Sheetwood Company Method for rapid manufacture of sheet lumber
US2548095A (en) * 1948-01-10 1951-04-10 New England Box Company Production of construction materials from wood and other vegetable fibers
US2635301A (en) * 1948-09-30 1953-04-21 Plywood Res Foundation Web or mat forming device
US2744848A (en) * 1954-03-29 1956-05-08 Long Bell Lumber Company Making fiberboard of uniform density and thickness
US2757114A (en) * 1954-11-08 1956-07-31 Weyerhaeuser Timber Co Manufacture of glazed hardboard
US2925360A (en) * 1957-08-29 1960-02-16 Weyerhaeuser Co Method of preventing excessive springback of dry felted fiber mats

Cited By (33)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3304356A (en) * 1964-04-18 1967-02-14 Kralinator Filters Ltd Method of producing plastic fiber filters
US3313002A (en) * 1965-08-04 1967-04-11 Du Pont Apparatus for heat treating sheet material
US3679790A (en) * 1966-12-12 1972-07-25 Alf Adolf Alfsen Method of finishing boards of vegetable material
US3975483A (en) * 1967-01-12 1976-08-17 Bernard Rudloff Process for manufacturing stratified materials
US3377220A (en) * 1967-06-09 1968-04-09 American Filtrona Corp Process for making stable elongated elements
US3709651A (en) * 1970-09-08 1973-01-09 Saint Gobain Apparatus for the production of shaped articles of expanded cohered granules of thermoplastic material, in particular polystyrene
US3850558A (en) * 1972-02-15 1974-11-26 Bordon Chem Co Installation for manufacturing resin based concrete
US4028457A (en) * 1973-04-16 1977-06-07 Domtar Limited Consolidation of dry formed webs
US3973893A (en) * 1973-04-26 1976-08-10 Southampton Manufacturing Company, Inc. Apparatus for continuously manufacturing boards
US3969459A (en) * 1973-07-18 1976-07-13 Champion International Corporation Fiberboard manufacture
US4056342A (en) * 1973-07-18 1977-11-01 Champion International Corporation Fiberboard manufacture
US4086316A (en) * 1974-03-12 1978-04-25 Eduard Kusters Process for the manufacture of flat sheets or webs
US3992135A (en) * 1975-07-07 1976-11-16 Southampton Manufacturing Company, Incorporated Apparatus for continuously manufacturing boards
US4025272A (en) * 1975-07-07 1977-05-24 Southampton Manufacturing Company, Inc. Apparatus for continuously manufacturing boards
US4096796A (en) * 1975-12-22 1978-06-27 Potlatch Corporation Apparatus and method for controlling press racking
US4216179A (en) * 1977-05-17 1980-08-05 Bison-Werke Bahre & Greten Gmbh & Co. Kg Process and an apparatus for the continuous manufacture of boards from material incorporating a heat hardenable binder
US4293509A (en) * 1978-12-15 1981-10-06 Bison-Werke Bahre & Greten Gmbh & Co. Kg Process for the production of chipboards, fiberboards, or like boards
US4255108A (en) * 1979-01-19 1981-03-10 Morrison-Knudsen Forest Products Company, Inc. Furnish handling apparatus
US4322380A (en) * 1979-01-19 1982-03-30 Morrison-Knudsen Forest Products Company, Inc. Method for feeding and orienting fibrous furnish
US4517147A (en) * 1984-02-03 1985-05-14 Weyerhaeuser Company Pressing process for composite wood panels
US4605467A (en) * 1984-03-29 1986-08-12 G. Siempelkamp Gmbh & Co. Apparatus for producing steam hardened pressedboard
US4626184A (en) * 1985-03-14 1986-12-02 Kimberly-Clark Corporation Scarfing apparatus
US4675144A (en) * 1985-03-14 1987-06-23 Kimberly-Clark Corporation Scarfing method
US6136239A (en) * 1994-01-28 2000-10-24 Valmet Fibertech Aktiebolag Method of manufacturing lignocellulosic board
US6054081A (en) * 1994-11-17 2000-04-25 Maschinenfabrik J. Dieffenbacher Gmbh & Co. Process for the continuous production of boards of wood-based material
US5762980A (en) * 1994-11-17 1998-06-09 Maschinenfabrik J. Dieffenbacher Gmbh & Co. Installation for the continuous production of boards of wood-based material
US5908596A (en) * 1994-12-21 1999-06-01 Nicofibers, Inc. Process and apparatus for expanding and molding fiberglass laminate and the panel formed thereby
US5695848A (en) * 1994-12-21 1997-12-09 Nicofibers, Inc. Panel formed from molded fiberglass strands
US5639411A (en) * 1994-12-21 1997-06-17 Holli-Nee Corporation Process for expanding glass fiber laminates and panels formed thereby
US6123884A (en) * 1995-04-07 2000-09-26 Valmet Fibertech Aktiebolag Method of manufacturing lignocellulosic board
US20050058818A1 (en) * 2003-09-12 2005-03-17 West D. David Laminated composite and process of making same
CN102452182A (zh) * 2010-10-22 2012-05-16 上海宝钢化工有限公司 一种用于压实粉状原料的辊带压实机
CN102452182B (zh) * 2010-10-22 2014-08-20 上海宝钢化工有限公司 一种用于压实粉状原料的辊带压实机

Also Published As

Publication number Publication date
GB999445A (en) 1965-07-28
DE1224919B (de) 1966-09-15
DE1224919C2 (cs) 1967-04-13
SE305313B (cs) 1968-10-21

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