Abstract: The present invention relates to the manufacture of a multilayered board having a stable, and moisture resistant surface. To accomplish this and other advantages of the invention, an improved binder system is used in the production of the surface layers of a multi-layered board which combines an excellent resin penetration inside the wood constituents of the board's surface layers, with a strength, durability and resitance to ambient water and moisture. The improved-binder system used in the production of the board surface layers accordinq to this invention involves contacting wood pieces with a binder composition comprised of a curable powdery aldehyde resin and a curable isocyanate resin in the substantial absence of free water to provide a composite mixture that can be formed into a surface layer for assembly and lamination together with other wood and resin composite layers.

Abstract: The present invention relates to the manufacture of a multi-layered board having a stable, and moisture-resistant surface. To accomplish this and other advantages of the invention, an improved binder system is used in the production of the surface layers of a multi-layered board which combines an. excellent resin penetration inside the wood constituents of the board's surface layers, with a strength, durability and resistance to ambient water and moisture. The improved binder system used in the production of the board surface layers according to this invention involves contacting wood pieces with a binder composition comprised of a curable powdery aldehyde resin and a curable isocyanate resin in the substantial absence of free water to provide a composite mixture that can be formed into a surface layer for assembly and lamination together with other wood and resin composite layers.

Abstract: Oriented strand board is post-fabrication treated with a polymeric coating which includes isocyanate constituents to produce a construction material which is smooth, has high gloss, and which is resistant to water, vapor, and chemical penetration. The isocyanate constituents are most preferably MDI or PMDI, and may be present in a coating composition alone or in combination with other binder materials such as PEEG or other polyols. Prior to application of the coating composition, the surface of the oriented strand board is pretreated using heat and pressure to compress and densify wood at the surface, and to smooth out minor surface irregularities. The coating composition is then applied to the wood surface, and is cured to form a polymeric coating which bonds to the wood material.

Abstract: A method and apparatus for molding articles such as pallets from flake-like wood particles mixed with binder, the pallets housing a deck and integral molding legs. A loosly fitted mat of wood flakes is formed by depositing a first plurality of layers of wood flakes onto a supporting surface with a flake aligners provided for causing alignment of those flakes which will form legs of the pallet. A second plurality of layers are formed with a flake aligner provided for causing alignment of flakes which will form the legs of the pallet and in a direction transverse to the direction of alignment of the flakes of the first layers.

Abstract: Flakeboard or particle board panels and other composite articles made from wood flakes or other particulate lignocellulosic materials having a relatively high internal bond and improved resistance to moisture are made from flakes or particles which have a moisture content of at least 15%. A catalyst capable of accelerating the reaction between the flakes or particles, the binder and water is applied to the flakes or particles prior to the addition of a moisture-tolerant particle board binder, such as an organic polyisocyanate. A mat of the resulting furnish is compression shaped under pressure and at a temperature less than 250.degree. F. for a time period sufficient to form a composite article of the desired shape and/or dimensions.

Abstract: A method for molding articles such as pallets from flake-like wood particles mixed with binder, the pallets housing a deck and integral molding legs. A loosely fitted mat of wood flakes is formed by depositing a first plurality of layers of wood flakes onto a supporting surface with a flake aligners provided for causing alignment of those flakes which will form legs of the pallet. A second plurality of layers are formed with a flake aligner provided for causing alignment of flakes which will form the legs of the pallet and in a direction transverse to the direction of alignment of the flakes of the first layers.