Abstract: A composite lumber product of consolidated comminuted wood and thermosetting resin made by a method which comprises densifying the material into a product-shaped heated metal mold by applying the compressing thrust in a direction parallel to the width dimension of the lumber-like article produced, rather than in the direction parallel the thickness dimension as in conventional hot platen pressing. Densifying in this manner produces much superior orientation of the wood grain along the long axis of the composite lumber product. The timed period elapsed during the densification to dimension now can be, and must be, quite short--of the order of twenty seconds or preferably less--allowing maximum heat transfer into the densified material from the hot metal broad-face (W.times.L) surface to thus minimize the presstime required. Apparatus for carrying out the method is disclosed.

Abstract: Phenol-formaldehyde and phenol-resorcinol-formaldehyde resinous aqueous syrups useful as thermosetting binders or adhesives are prepared by reacting, a phenol-formaldehyde resin composition firstly at atmospheric reflux temperature at a substantially neutral pH of 5.8 to 8.5 and a formaldehyde to phenol mol ratio between 1.7 to 2.8 for a period of 20 to 120 minutes; reacting secondly with added formaldehyde, if necessary, and also needed alkali metal hydroxide to produce mol ratios of 2.1 to 2.8 and 0.10 to 0.38, respectively, per mol of phenol, for a period of at least two minutes at reflux to produce a liquid phenol-formaldehyde thermosetting resin. The setting time can be decreased, if desired, by using two portions of syrup, reacting one portion for a greater time-temperature period than the other and combining the two portions.

Abstract: A composite railroad tie of structurally distinct components adhesively joined in layers to form a unit. At least one of the components being of high density phenolformaldehyde bonded particleboard manufactured in a platen press with heat. At least two elements disposed close to and parallel the broad surfaces are composed of lumber with grain direction oriented parallel the long axis. A remaining centermost element, affixed to the above two lumber elements, is relatively non-critical, being selected from lumber or particleboard of adequate shear and compressive strength on the basis of availability, cost, ease of treatment with preservative, etc.

Abstract: Novel stable-in-use aminoplast resin binder solutions comprising aqueous solutions of predominantly a urea-formaldehyde resin having a formaldehyde to urea ratio of less than 2.0, from about 40 to 56% by weight dissolved ammonium polyphosphate reacted with 5 to 12.5 percent by weight formaldehyde and not more than 30% by weight water. Preferred aminoplast resin binder solutions also contain a methylolated melamine-formaldehyde resin. A novel process for the production of the stable aminoplast resin binder solutions containing high percentages of ammonium polyphosphates and suitable for production of fire-retardant particle board is disclosed.