WO2018106695A1 - Method of manufacturing osb with acoustic dampening properties - Google Patents

Method of manufacturing osb with acoustic dampening properties Download PDF

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Publication number
WO2018106695A1
WO2018106695A1 PCT/US2017/064722 US2017064722W WO2018106695A1 WO 2018106695 A1 WO2018106695 A1 WO 2018106695A1 US 2017064722 W US2017064722 W US 2017064722W WO 2018106695 A1 WO2018106695 A1 WO 2018106695A1
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WO
WIPO (PCT)
Prior art keywords
noise
strands
reducing polymer
layer
lignocellulosic
Prior art date
Application number
PCT/US2017/064722
Other languages
French (fr)
Inventor
Ashwin HIMATSINGANI
Jianwen Ni
Original Assignee
Louisiana-Pacific Corporation
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Louisiana-Pacific Corporation filed Critical Louisiana-Pacific Corporation
Priority to CA3045151A priority Critical patent/CA3045151A1/en
Priority to BR112019011495-5A priority patent/BR112019011495B1/en
Priority to EP17878502.8A priority patent/EP3548279A4/en
Publication of WO2018106695A1 publication Critical patent/WO2018106695A1/en

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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
    • B27N3/04—Manufacture of substantially flat articles, e.g. boards, from particles or fibres from fibres
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L97/00—Compositions of lignin-containing materials
    • C08L97/02—Lignocellulosic material, e.g. wood, straw or bagasse
    • 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
    • B27N1/00—Pretreatment of moulding material
    • 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
    • B27N3/002—Manufacture of substantially flat articles, e.g. boards, from particles or fibres characterised by the type of binder
    • 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
    • B27N3/02—Manufacture of substantially flat articles, e.g. boards, from particles or fibres from particles
    • 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
    • B27N3/143—Orienting the particles or fibres
    • 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
    • B27N3/18—Auxiliary operations, e.g. preheating, humidifying, cutting-off
    • 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
    • B27N7/00—After-treatment, e.g. reducing swelling or shrinkage, surfacing; Protecting the edges of boards against access of humidity
    • 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
    • B32B21/13—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board all layers being exclusively wood
    • 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
    • B32B21/14—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood board or veneer
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • 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
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B1/86—Sound-absorbing elements slab-shaped
    • G—PHYSICS
    • G10—MUSICAL INSTRUMENTS; ACOUSTICS
    • G10K—SOUND-PRODUCING DEVICES; METHODS OR DEVICES FOR PROTECTING AGAINST, OR FOR DAMPING, NOISE OR OTHER ACOUSTIC WAVES IN GENERAL; ACOUSTICS NOT OTHERWISE PROVIDED FOR
    • G10K11/00—Methods or devices for transmitting, conducting or directing sound in general; Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/16—Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/162—Selection of materials
    • G10K11/168—Plural layers of different materials, e.g. sandwiches
    • 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
    • B27N1/00—Pretreatment of moulding material
    • B27N1/02—Mixing the material with binding agent
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 layers
    • 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
    • B32B2255/00—Coating on the layer surface
    • B32B2255/08—Coating on the layer surface on wood 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
    • B32B2255/00—Coating on the layer surface
    • B32B2255/24—Organic non-macromolecular coating
    • 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
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/026—Wood 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • 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
    • B32B2262/067—Wood fibres
    • 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
    • B32B2307/10—Properties of the layers or laminate having particular acoustical 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • 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
    • 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
    • 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
    • B32B2419/00—Buildings or parts thereof
    • 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
    • B32B2419/00—Buildings or parts thereof
    • B32B2419/06—Roofs, roof membranes
    • 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
    • B32B2607/00—Walls, panels
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B2001/8457—Solid slabs or blocks
    • E04B2001/8461—Solid slabs or blocks layered

Definitions

  • This invention relates to a method and system for manufacturing wood products (such as OSB, oriented strand board) with acoustic dampening properties.
  • Airborne noise/STC Sound Transmission Class
  • impact noise Impact Insulation Class, IIC rating in wall and floor or ceiling assemblies often is specified in codes and standards by ANSI, IgCC and LEED.
  • Airborne noise from outside or inside the living space has been addressed with various field-applied and pre-fabricated noise dampening constructions products, such as resilient channels, clips, staggered studs, multiple layers of drywall, wall cavity insulation, and laminated acoustic drywall.
  • Acoustic materials have been used to laminate two panels of various building materials through a secondary process to improve acoustic performance.
  • building materials such as OSB-based siding, sheathing, roofing or flooring, that incorporate a sound dampening material in the primary manufacturing process of panels with improved acoustic performance.
  • the present invention comprises a method or process for manufacturing wood products with acoustic dampening properties.
  • the manufactured wood product include, but are not limited to, oriented strand board (OSB), LSL, MDF, particleboard, or various wood composites.
  • the system introduces a noise- dampening polymer in-line in the manufacturing process to achieve higher acoustic performance (e.g., STC and IIC rating) in siding, sheathing, roofing, flooring, and similar applications using the manufactured wood product.
  • the polymer can be a viscoelastic polymer which is added during blending or formation of the wood product. In one exemplary embodiment, as described in greater detail below, viscoelastic polymer is added to the center strand layer during the OSB manufacturing process.
  • General elements of the OSB manufacturing process include the drying and storing of wood strands, the treatment or blending of designated strands (e.g., bottom, core, top) with applicable chemicals or additives (e.g., wax, resin binders, and the like) the forming of the appropriate layers in order (first bottom surface, then core, then top surface) using designated strands, the application of heat and pressure to the mats to form boards, and subsequent processing (e.g., panels cut to size, edges sealed, and packaging) to produce the finished product.
  • the core strands are coated with the noise-dampening polymer in a strand blender or blender.
  • the polymer can be blended with the core strands separately, or along with other additives typically added during the OSB process, such as waxes or resin binders. These treated core strands are used to form the central layer, sandwiched between the bottom surface and top surface.
  • the finished product is an OSB panel with a central layer with core strands blended with the noise-dampening acoustic material or materials. This coating by blending can also take place for strands in other layers.
  • the noise-dampening acoustic material or materials are applied through a spraying, flow, curtain, or other coating process in the forming line before, during or after the center strand layer is laid on the forming line. This coating can also take place for strands in other layers.
  • the finished product is an OSB or manufactured wood panel with a central layer with core strands (and possibly other layers) integrally coated, permeated or infused with the noise-dampening acoustic material or materials.
  • Figure 1 shows a view of a system in accordance with an embodiment of the present invention.
  • FIG. 2 shows another system in accordance with another embodiment of the present invention.
  • FIG. 3 shows another system in accordance with another embodiment of the present invention.
  • the present invention comprises a method or process for manufacturing wood products with acoustic dampening properties.
  • the manufactured wood product include, but are not limited to, oriented strand board (OSB), LSL, MDF, particleboard, or various wood composites.
  • the present invention comprises a system for introducing a noise-dampening polymer in-line in the manufacturing process to achieve higher acoustic performance (e.g., STC and/or IIC rating) in siding, sheathing, roofing, flooring, and similar applications using the manufactured wood product.
  • the polymer can be a viscoelastic polymer which is added during blending or formation of the wood product. In one exemplary embodiment, as described in greater detail below, viscoelastic polymer is added to the center strand layer during the OSB manufacturing process.
  • General elements of the OSB manufacturing process in accordance with the present invention include the drying and storing of wood strands 10, the treatment or blending of designated strands (e.g., bottom, core, top) with applicable chemicals and/or additives (e.g., wax, resin, and the like) 30, the forming of the appropriate layers in order (first bottom surface, then core, then top surface) using designated strands, 30, 40, 50, the application of heat and pressure to the mats using a primary press to form boards 60, and subsequent trimming 70 and processing (e.g., panels cut to size, edges primed/sealed, and packaging) 80 to produce the finished product 100.
  • designated strands e.g., bottom, core, top
  • applicable chemicals and/or additives e.g., wax, resin, and the like
  • Strands for a particular layer typically are blended with applicable chemicals and/or additives in a bin, separate from strands for other layers, although this is not always the case.
  • Examples of primary processes are described in U.S. Pat. Nos. 6,461,743; 5,718,786; 5,525,394; 5,470,631; and 5,425,976; all of which are incorporated herein in their entireties by specific reference for all purposes.
  • Figure 2 shows an embodiment of the manufacturing process where the core strands are coated with the noise-dampening polymer in a strand blender or blenders 120.
  • the top and bottom surface strands are blended separately 20a, although in some embodiments, one or both sets of strands also may be blended with a noise-dampening polymer.
  • the polymer can be blended with the core strands separately, or along with other additives typically added during the OSB process, such as waxes or resin binders.
  • the treated core strands are used to form the central core layer 140, sandwiched between the bottom surface and top surface.
  • the finished product is an OSB panel (or other manufactured wood product) with a core layer with core strands blended with the noise- dampening acoustic material or materials.
  • the heat and pressure applied during the primary pressing process prmotes the noise-dampening acoustic material to integrally coat, permeate or infuse the core layer, and in several embodiments, portions of the bottom and/or top
  • Figure 3 shows another second embodiment of the manufacturing process where, after blending of the strands 20a, b, the noise-dampening acoustic material or materials are applied through a spraying, flow, curtain or other coating process 240 in the forming line before, during, or after the center core strand layer is laid on the forming line.
  • the finished product is an OSB panel (or other manufactured wood product) with a central layer with core strands coated with the noise-dampening acoustic material or materials.
  • the heat and pressure applied during the primary pressing process promotes the noise-dampening acoustic material to integrally coat, permeate or infuse the core layer, and in several embodiments, portions of the bottom and/or top surface layers.
  • Binders include, but are not limited to, isocyanate resin, urea-formaldehyde, phenol formaldehyde, melamine formaldehyde, bio- adhesives, or combinations thereof.
  • polymeric isocyanate resin (pMDI, or polymeric diphenylmethane diisocyanate) is used at about 1.2 to about 20 weight %.
  • Waxes include, but are not limited to, a molten wax or emulsion was (in one embodiment, up to about 2.5 weight %).
  • Other chemicals or additives may be used, including, for example, fire retardants, weather-resistant chemicals, or the like.
  • Viscoelastic polymer is added as described above to the center layer or any other layer in the mat. Press time is from 1 to 20 minutes at a temperature from about 100° C to about 240° C.
  • the resulting panel can range in thickness from about 1 ⁇ 4" to about 7", and in density from about 25 pcf to about 60 pcf (pounds per cubic foot).
  • the thickness and/or density of the top or bottom strand layer, or both can be modified as well to achieve an improved acoustic performance/STC rating.
  • the present invention thus provides an OSB or manufactured wood panel with a noise-dampening polymer introduced in-line, with a resulting increase (1) in acoustic performance as compared to a standard OSB panel, and (2) in efficiency and reduction in cost compared to secondary manufacturing processes.
  • the noise- dampening polymer becomes integrated with, and infuses or permeates the layer or layers of the panel.
  • the noise-dampening of the present invention applies to both airborne sound transmission loss and impact sound insulation.
  • panels produced in accordance with the present invention smooth airborne sound transmission loss curves in the ASTM E90 test method, particularly increasing loss (dB) in frequency ranges where sound is transmitted more effectively due to physical characteristics (i.e., of a similar panel but without the sound-dampening agent).
  • the present invention increases airborne transmission loss in the sound frequency ranges of from about 1.5K to about 4K Hz (more particularly, from about 2K to about 3.2K Hz, or even more particularly, from about 2.5K to about 3.15K Hz).
  • panels produced in accordance with the present invention demonstrate increased impact sound insulation and decreased sound pressure levels.
  • such panels have a tested apparent impact insulation class (AIIC) rating in the range from about 26 to about 34, as determined by ASTM Standard E-1007 (2016).
  • AIIC apparent impact insulation class
  • a control panel without noise-dampening polymer had an AIIC rating of 19.

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  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Wood Science & Technology (AREA)
  • Physics & Mathematics (AREA)
  • Manufacturing & Machinery (AREA)
  • Forests & Forestry (AREA)
  • Acoustics & Sound (AREA)
  • Chemical & Material Sciences (AREA)
  • Architecture (AREA)
  • Medicinal Chemistry (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Health & Medical Sciences (AREA)
  • Polymers & Plastics (AREA)
  • Electromagnetism (AREA)
  • Materials Engineering (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Multimedia (AREA)
  • Laminated Bodies (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Soundproofing, Sound Blocking, And Sound Damping (AREA)
  • Oil, Petroleum & Natural Gas (AREA)

Abstract

A manufacturing process for manufacturing wood products with acoustic dampening properties. A noise-dampening polymer is introduced in-line in the manufacturing process to achieve higher acoustic performance. The polymer can be a viscoelastic polymer which is added during blending of the lignocellulosic strands prior to mat formation, or sprayed or otherwise coated on the lignocellulosic strands during mat formation, prior to formation of any boards or panels.

Description

METHOD OF MANUFACTURING OSB WITH ACOUSTIC DAMPENING
PROPERTIES
This application claims benefit of and priority to U.S. Provisional Application No. 62/429,896, filed December 5, 2016, and is entitled to that filing date for priority. The specification, figures, and complete disclosure of U.S. Provisional Application No. 62/429,896 are incorporated herein in their entireties by specific reference for all purposes. FIELD OF INVENTION
This invention relates to a method and system for manufacturing wood products (such as OSB, oriented strand board) with acoustic dampening properties. BACKGROUND OF THE INVENTION
Acoustic comfort is important in building design. Noise is the often the primary complaint by home owners in residential single-family homes, and noise reduction also is an important performance criterion in multi-family and commercial construction (particularly in the healthcare and education segments). Airborne noise/STC (Sound Transmission Class) rating and impact noise (Impact Insulation Class, IIC) rating in wall and floor or ceiling assemblies often is specified in codes and standards by ANSI, IgCC and LEED.
Airborne noise from outside or inside the living space has been addressed with various field-applied and pre-fabricated noise dampening constructions products, such as resilient channels, clips, staggered studs, multiple layers of drywall, wall cavity insulation, and laminated acoustic drywall. Acoustic materials have been used to laminate two panels of various building materials through a secondary process to improve acoustic performance. However, there are no building materials, such as OSB-based siding, sheathing, roofing or flooring, that incorporate a sound dampening material in the primary manufacturing process of panels with improved acoustic performance.
SUMMARY OF THE INVENTION
In various exemplary embodiments, the present invention comprises a method or process for manufacturing wood products with acoustic dampening properties. The manufactured wood product include, but are not limited to, oriented strand board (OSB), LSL, MDF, particleboard, or various wood composites. The system introduces a noise- dampening polymer in-line in the manufacturing process to achieve higher acoustic performance (e.g., STC and IIC rating) in siding, sheathing, roofing, flooring, and similar applications using the manufactured wood product. The polymer can be a viscoelastic polymer which is added during blending or formation of the wood product. In one exemplary embodiment, as described in greater detail below, viscoelastic polymer is added to the center strand layer during the OSB manufacturing process.
General elements of the OSB manufacturing process include the drying and storing of wood strands, the treatment or blending of designated strands (e.g., bottom, core, top) with applicable chemicals or additives (e.g., wax, resin binders, and the like) the forming of the appropriate layers in order (first bottom surface, then core, then top surface) using designated strands, the application of heat and pressure to the mats to form boards, and subsequent processing (e.g., panels cut to size, edges sealed, and packaging) to produce the finished product. In a first embodiment of the manufacturing process, the core strands are coated with the noise-dampening polymer in a strand blender or blender. The polymer can be blended with the core strands separately, or along with other additives typically added during the OSB process, such as waxes or resin binders. These treated core strands are used to form the central layer, sandwiched between the bottom surface and top surface. The finished product is an OSB panel with a central layer with core strands blended with the noise-dampening acoustic material or materials. This coating by blending can also take place for strands in other layers.
In another exemplary embodiment, the noise-dampening acoustic material or materials are applied through a spraying, flow, curtain, or other coating process in the forming line before, during or after the center strand layer is laid on the forming line. This coating can also take place for strands in other layers.
The finished product is an OSB or manufactured wood panel with a central layer with core strands (and possibly other layers) integrally coated, permeated or infused with the noise-dampening acoustic material or materials.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 shows a view of a system in accordance with an embodiment of the present invention.
Figure 2 shows another system in accordance with another embodiment of the present invention.
Figure 3 shows another system in accordance with another embodiment of the present invention. DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
In various exemplary embodiments, the present invention comprises a method or process for manufacturing wood products with acoustic dampening properties. The manufactured wood product include, but are not limited to, oriented strand board (OSB), LSL, MDF, particleboard, or various wood composites.
In several embodiments, the present invention comprises a system for introducing a noise-dampening polymer in-line in the manufacturing process to achieve higher acoustic performance (e.g., STC and/or IIC rating) in siding, sheathing, roofing, flooring, and similar applications using the manufactured wood product. The polymer can be a viscoelastic polymer which is added during blending or formation of the wood product. In one exemplary embodiment, as described in greater detail below, viscoelastic polymer is added to the center strand layer during the OSB manufacturing process.
General elements of the OSB manufacturing process in accordance with the present invention, as seen in Figures 1 and 2, include the drying and storing of wood strands 10, the treatment or blending of designated strands (e.g., bottom, core, top) with applicable chemicals and/or additives (e.g., wax, resin, and the like) 30, the forming of the appropriate layers in order (first bottom surface, then core, then top surface) using designated strands, 30, 40, 50, the application of heat and pressure to the mats using a primary press to form boards 60, and subsequent trimming 70 and processing (e.g., panels cut to size, edges primed/sealed, and packaging) 80 to produce the finished product 100. Strands for a particular layer typically are blended with applicable chemicals and/or additives in a bin, separate from strands for other layers, although this is not always the case. Examples of primary processes are described in U.S. Pat. Nos. 6,461,743; 5,718,786; 5,525,394; 5,470,631; and 5,425,976; all of which are incorporated herein in their entireties by specific reference for all purposes.
Figure 2 shows an embodiment of the manufacturing process where the core strands are coated with the noise-dampening polymer in a strand blender or blenders 120. The top and bottom surface strands are blended separately 20a, although in some embodiments, one or both sets of strands also may be blended with a noise-dampening polymer. The polymer can be blended with the core strands separately, or along with other additives typically added during the OSB process, such as waxes or resin binders. The treated core strands are used to form the central core layer 140, sandwiched between the bottom surface and top surface. The finished product is an OSB panel (or other manufactured wood product) with a core layer with core strands blended with the noise- dampening acoustic material or materials. The heat and pressure applied during the primary pressing process prmotes the noise-dampening acoustic material to integrally coat, permeate or infuse the core layer, and in several embodiments, portions of the bottom and/or top surface layers.
Figure 3 shows another second embodiment of the manufacturing process where, after blending of the strands 20a, b, the noise-dampening acoustic material or materials are applied through a spraying, flow, curtain or other coating process 240 in the forming line before, during, or after the center core strand layer is laid on the forming line. The finished product is an OSB panel (or other manufactured wood product) with a central layer with core strands coated with the noise-dampening acoustic material or materials. As described above, the heat and pressure applied during the primary pressing process promotes the noise-dampening acoustic material to integrally coat, permeate or infuse the core layer, and in several embodiments, portions of the bottom and/or top surface layers.
The components and parameters of the above processes can vary. In one exemplary embodiment, the wood strands can be derived from hard (e.g., aspen) or soft (e.g., southern yellow pine) woods, and can be homogenous (i.e., single wood type) or mixed, and green (moisture content from about 30% to about 200%) or dried (e.g.., moisture content up to about 12%) (where moisture content % = (weight of water in wood/oven-dry weight of wood) x 100). Binders include, but are not limited to, isocyanate resin, urea-formaldehyde, phenol formaldehyde, melamine formaldehyde, bio- adhesives, or combinations thereof. In one embodiment, polymeric isocyanate resin (pMDI, or polymeric diphenylmethane diisocyanate) is used at about 1.2 to about 20 weight %. Waxes include, but are not limited to, a molten wax or emulsion was (in one embodiment, up to about 2.5 weight %). Other chemicals or additives may be used, including, for example, fire retardants, weather-resistant chemicals, or the like. Viscoelastic polymer is added as described above to the center layer or any other layer in the mat. Press time is from 1 to 20 minutes at a temperature from about 100° C to about 240° C. The resulting panel can range in thickness from about ¼" to about 7", and in density from about 25 pcf to about 60 pcf (pounds per cubic foot).
In any of the above embodiments, the thickness and/or density of the top or bottom strand layer, or both, can be modified as well to achieve an improved acoustic performance/STC rating. The present invention thus provides an OSB or manufactured wood panel with a noise-dampening polymer introduced in-line, with a resulting increase (1) in acoustic performance as compared to a standard OSB panel, and (2) in efficiency and reduction in cost compared to secondary manufacturing processes. The noise- dampening polymer becomes integrated with, and infuses or permeates the layer or layers of the panel.
In several embodiments, the noise-dampening of the present invention applies to both airborne sound transmission loss and impact sound insulation. In some embodiments, panels produced in accordance with the present invention smooth airborne sound transmission loss curves in the ASTM E90 test method, particularly increasing loss (dB) in frequency ranges where sound is transmitted more effectively due to physical characteristics (i.e., of a similar panel but without the sound-dampening agent). In one embodiment, the present invention increases airborne transmission loss in the sound frequency ranges of from about 1.5K to about 4K Hz (more particularly, from about 2K to about 3.2K Hz, or even more particularly, from about 2.5K to about 3.15K Hz).
In additional embodiments, panels produced in accordance with the present invention demonstrate increased impact sound insulation and decreased sound pressure levels. In one embodiment, such panels have a tested apparent impact insulation class (AIIC) rating in the range from about 26 to about 34, as determined by ASTM Standard E-1007 (2016). In contrast, a control panel without noise-dampening polymer had an AIIC rating of 19.
Thus, it should be understood that the embodiments and examples described herein have been chosen and described in order to best illustrate the principles of the invention and its practical applications to thereby enable one of ordinary skill in the art to best utilize the invention in various embodiments and with various modifications as are suited for particular uses contemplated. Even though specific embodiments of this invention have been described, they are not to be taken as exhaustive. There are several variations that will be apparent to those skilled in the art.

Claims

CLAIMS What is claimed is:
1. A method for producing a noise-dampening manufactured wood product, comprising the steps of:
treating a set of bottom layer lignocellulosic strands with one or more chemicals or additives;
treating a set of core layer lignocellulosic strands with one or more chemicals or additives;
treating a set of top layer lignocellulosic strands with one or more chemicals or additives;
adding, in a manufacturing production line, a noise-reducing polymer with the lignocellulosic strands in one or more of said layer sets;
forming a multilayer mat with said treated layer sets; and
applying heat and pressure to the multilayer mat to form one or more boards.
2. The method of claim 1, further comprising the step of post-press processing of the one or more boards to produce one or more panels.
3. The method of claim 2, wherein the one or more panels are OSB panels.
4. The method of claim 1, wherein the noise-reducing polymer is a viscoelastic polymer.
5. The method of claim 1, wherein the noise-reducing polymer is added to the set of core layer lignocellulosic strands.
6. The method of claim 1, wherein the step of adding the noise-reducing polymer comprises blending the noise-reducing polymer with the lignocellulosic strands prior to formation of the multilayer mat.
7. The method of claim 1, wherein the step of adding the noise-reducing polymer comprises spraying, flowing, curtain or otherwise coating one or more layers of the multilayer mat with the noise-reducing polymer during formation of the multilayer mat.
8. A manufactured wood product, comprising a panel with noise-dampening properties formed according the method of claim 1.
9. A manufactured wood product, comprising:
a panel with multiple lignocellulosic strand-based layers, wherein one or more layers comprise a noise-reducing polymer integrated with the lignocellulosic strands forming said one or more layer.
10. The manufactured wood product of claim 9, wherein the multiple layers comprise a bottom layer, a core layer, and a top layer.
11. The manufactured wood product of claim 10, wherein the noise-reducing polymer is integrated with the strands forming the core layer.
PCT/US2017/064722 2016-12-05 2017-12-05 Method of manufacturing osb with acoustic dampening properties WO2018106695A1 (en)

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CA3045151A CA3045151A1 (en) 2016-12-05 2017-12-05 Method of manufacturing osb with acoustic dampening properties
BR112019011495-5A BR112019011495B1 (en) 2016-12-05 2017-12-05 METHOD FOR MANUFACTURING A MANUFACTURED WOOD PRODUCT AND MANUFACTURED WOOD PRODUCT
EP17878502.8A EP3548279A4 (en) 2016-12-05 2017-12-05 Method of manufacturing osb with acoustic dampening properties

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US201662429896P 2016-12-05 2016-12-05
US62/429,896 2016-12-05

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BR112019011495A2 (en) 2019-11-05
US20180345531A1 (en) 2018-12-06
EP3548279A1 (en) 2019-10-09
CA3045151A1 (en) 2018-06-14
US20220105656A1 (en) 2022-04-07
EP3548279A4 (en) 2020-09-09
CL2019001534A1 (en) 2020-01-17

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