Abstract: A method and apparatus for producing a synthetic board from cellulosic or lignocellulosic fibers is disclosed wherein a standard isocyanate binder is emulsified and immediately applied to the fibers before consolidation into a finished board product. The apparatus includes an emulsification and application nozzle comprising a diluent inlet, a binder inlet, a mixing section for emulsifying the diluent and the binder, and a spray nozzle for applying the binder/diluent emulsion to the fibers. The method includes supplying a binder stream, supplying a diluent stream, emulsifying the binder with the diluent and immediately applying the emulsion to the fibers. The method further includes flushing the binder/diluent emulsion using the diluent at the end of a binder application run to prevent curing of the emulsion and clogging of the apparatus. The binder/diluent emulsion can be applied to the fibers either in the blowline or downstream of the blowline, such as in the blender.

Abstract: A method and apparatus for producing a synthetic board from cellulosic or lignocellulosic fibers is disclosed wherein a standard isocyanate binder is emulsified and immediately applied to the fibers before consolidation into a finished board product. The apparatus includes an emulsification and application nozzle comprising a diluent inlet, a binder inlet, a mixing section for emulsifying the diluent and the binder, and a spray nozzle for applying the binder/diluent emulsion to the fibers. The method includes supplying a binder stream, supplying a diluent stream, emulsifying the binder with the diluent and immediately applying the emulsion to the fibers. The method further includes flushing the binder/diluent emulsion using the diluent at the end of a binder application run to prevent curing of the emulsion and clogging of the apparatus. The binder/diluent emulsion can be applied to the fibers either in the blowline or downstream of the blowline, such as in the blender.

Abstract: A method and apparatus for producing a synthetic board from cellulosic or lignocellulosic fibers is disclosed wherein a standard isocyanate binder is emulsified and immediately applied to the fibers before consolidation into a finished board product. The apparatus includes an emulsification and application nozzle comprising a diluent inlet, a binder inlet, a mixing section for emulsifying the diluent and the binder, and a spray nozzle for applying the binder/diluent emulsion to the fibers. The method includes supplying a binder stream, supplying a diluent stream, emulsifying the binder with the diluent and immediately applying the emulsion to the fibers. The method further includes flushing the binder/diluent emulsion using the diluent at the end of a binder application run to prevent curing of the emulsion and clogging of the apparatus. The present invention can be used to apply the binder/diluent emulsion to the fibers either in the blowline or downstream of the blowline, such as in the blender.