Abstract: A waferboard panel is made from long wafers to have the same strength properties as plywood. The panel comprises at least three layers of wood wafers having an initial aggregate specific gravity, less than about 0.6 oven dry weight with volume at 12% moisture content, the panel having face layers on outside surfaces and at least one core layer. The wafers in the face layers have a mean orientation not greater than about 10.degree., and lengths of at least about 6 inches, preferably 12 inches. Average widths of the wafers in the face layers are in the range of about 0.3 to 2.0 inches and the panel has an oven dry wood density in the range of about 28 to 45 lbs. per cu. ft. with an MOR to density ratio of at least about 120 and an MOE (M) to density ratio of at least about 40.

Abstract: A phenol-resorcinol-formaldehyde resin and a method for making the same. In this method phenol and formaldehyde at an initial pH of 8.5 to 9.2 are reacted in the presence of a sodium sulfite catalyst. The reaction mixture is heated and refluxed until it has a viscosity of u-v on the Gardner bubble test. Additional resorcinol is added to the mixture and refluxing is continued until it has a viscosity of 30 to 100 Garner sections. The reaction mixture is diluted with a water miscible solvent to obtain a resin solution having a solids content of about 40 to 60 percent by weight and a viscosity of 2.0 to 3.5 poise. An alkali metal carbonate material in the amount of 4 to 8 percent by weight of the resin is added to make adhesives including this resin fast curing. Fumed silica is also added to the resin solution by means of high shear apparatus to make the solution thixotropic.

Abstract: Aqueous heat-curable compositions which are based on known heat-curable condensation products of aldehydes and OH- and/or NH.sub.2 -containing compounds, which contain hemicellulose-cleavage products having an average degree of polymerization, DP, of 5 to 100 and of at least 10% by weight, relative to the total weight of heat-curable materials, and aldehydes, in an amount of 5 to 50% by weight, relative to the weight of hemicellulose-cleavage products. The invention also relates to the use of these compositions for glueing and for preparing moldings.

Abstract: The dimensional stability of a composite wood panel having two surface wood veneer sheets with their grains disposed in the same direction and a core of adhesively bonded biomass particles such as processed wood particles is improved by including a third wood veneer sheet having its grain substantially perpendicular to the grains of the surface veneer sheets substantially centrally disposed in the core between the surface veneer sheets. The panel may be used as a wood structural panel in buildings, in furniture, or the like.

Abstract: The present invention concerns our discovery that aqueous cellulosic slurries comprising primary binder, newsprint, sulfite pulp, and vegetable shell flour can be prepared and formed as desired into various configurations. The materials thus formed are usable for a variety of purposes including furniture, paneling and flooring structures.

Abstract: A process for bonding lignocellulose raw materials using an isocyanate group-containing urethane-modified diphenylmethane diisocyanate mixture having a viscosity of 120 to 1000 mPas at 25.degree. C. and an isocyanate content of 15 to 33.6 percent by weight which is obtained by reacting a diphenylmethane diisocyanate mixture containing 10 to 75 percent by weight of 2,4'-diphenylmethane diisocyanate with 0.05 to 0.5 hydroxyl equivalents of a polyol per equivalent isocyanate group.

Abstract: A laminated wood coupling arrangement for fabricating unitary laminated wood joints. Two sets of multiple layers of thin wood strips placed at a 90.degree. angle to each other overlap ends in alternating layers. Glue placed between all adjacent surfaces retains the laminate together. The bottom layer has two strips. One strip butts against the end of the side of the other strip. The second layer above also has two strips with one crossing over the butt joint of the first layer. The other strip in the second layer butts against the end of the side of the cross over strip. Additional layers may be added in this alternating arrangement to achieve any desired strength or aesthetic appearance.

Abstract: A process for the manufacture of triple- and multi-layer particle board employing phenol formaldehyde resin compositions for gluing particles in the outer layers of the board characterized by the use of a phenol formaldehyde resin composition having a viscosity of about 30-90 seconds (4-mm DIN cup), a solids content of between about 30 and 39 percent by weight and an alkali content of less than 8 percent by weight is provided.

Abstract: A modified phenol-formaldehyde binding resin is particularly useful in the formation of man-made boards including bonded fibers, fibrous particles, and a plurality of uniformly, or randomly shaped pieces, masses or sheets bonded together with the modified phenol-formaldehyde binding resin. The resin binder is especially adapted to bonding wood fibers and particles, comprising the condensation product of a phenol, formaldehyde and a water-soluble carbohydrate-phenol complex from steam digestion of wood chips, and the production thereof. Various objects can be manufactured using these resins, such as particle objects and objects or sheet materials made by bonding together a plurality of uniformly or randomly shaped masses, for example, fiberboards such as hardboard and insulation board; particle board; plywood; oriented strand board; and waferboard.

Abstract: The invention is a method of reducing formaldehyde emission from wood-based composite boards bonded with aminoplast resins. A salt mixture comprising urea, or one of its analogs, a readily decomposible ammonia liberating compound and, alternatively, a resin catalyst is prepared in a finely granulated form. This is then added to the dried wood particles and blended, preferably prior to the addition of the adhesive binder resin. The salt mixture comprises 12-20 parts of the ammonia liberating compound, 65-88 parts of urea or its analog, and 0-15% of the catalyst. From 6-22.5% by weight of this mixture is used, based on resin solids. Formaldehyde evolution is reduced by 45-80% compared with untreated particleboard without adverse effect on physical properties or press time.

Abstract: Tree foliage extracts, their extraction processes, and the use of such extracts in formulating resins suitable for use in plywood adhesives and as wood bonding agents.

Abstract: This application discloses a phenol-formaldehyde binding resin formed from phenol and formaldehyde in mole ratio of one mole of phenol to 2 to 3 moles of formaldehyde, the resin being modified by replacing from 5% to 50% of the phenol by an equivalent amount of a concentrated aqueous complex of phenolic and carbohydrate components from the process water from the steam digestion of wood chips without chemical addition, said resin being formed by heating said mixture of phenol, formaldehyde and aqueous complex with aqueous alkali to a temperature not exceeding about 100.degree. C. until a resin having a Brookfield viscosity of at least 35 centipoises is produced, all weights being determined on a dry basis; and a method of producing said resin by reacting a concentrated aqueous extract obtained from the steam digestion of wood chips with phenol and formaldehyde under alkaline conditions at a temperature not exceeding about 100.degree. C.

Abstract: Wood is preserved with a water-based treating solution containing a halogenated phenol wood preservative such as pentachlorophenol, a phenolic resin prepolymer such as a phenol formaldehyde prepolymer, and a coupling or solubilizing agent for enhancing the water compatibility of the various ingredients. The treatment is carried out by exposing the wood, while submerged in the treating solution, so one or more cycles of reduced pressure (i.e. vacuum) and elevated pressure.

Abstract: The invention is an improved hardener for use with phenolresorcinol-formaldehyde wood bonding adhesives. The hardener is conveniently made and shipped as a stable dry powdered material. It is then slurried in water at the point of use for convenience with continuously mixed and dispensed liquid-liquid, two part adhesive systems. The hardener comprises paraformaldehyde or alphapolyoxymethylene, fillers, viscosity and/or rheology control agents, and a solid acidic material. The latter ingredient is a critical component used to adjust the pH of an aqueous slurry to the range of 4.0 to 5.5. Oxalic acid is preferred. In this pH range, the formaldehyde polymers are stable and the slurried hardener does not give off significant formaldehyde odor for periods up to several days. Bonding performance is improved because the characteristics of the hardener and resulting adhesive have very little variation over time.

Abstract: A method of resurfacing a worn wooden bowling lane comprises the steps of (a) smoothing the worn lane surface to a uniform level, (b) securing suitable underlayment panels to the surface of selected lane sections exposed to direct ball impact, (c) securing decorative panels of intermediate-density resin-bonded particle board to the surface of the remaining lane sections exposed only to rolling ball contact, and (d) securing a decorative, impact- and abrasion-resistant plastic laminate to the underlayment panels. The decorative panels simulate the appearance and bowling characteristics of natural wooden lanes.

Abstract: A bowling lane comprises a plurality of sections of longitudinally extending laminated panels supported by a foundation having means for leveling the lane sections during installation. The panels each have a decoratively printed upper surface of a plastic laminate or polyurethane which simulates the appearance and bowling characteristics of natural wooden lanes.

Abstract: Wood is preserved with a water-based treating solution containing a halogenated phenol wood preservative such as pentachlorphenol, a phenolic resin prepolymer such as a phenol formaldehyde prepolymer, and a coupling or solubilizing agent for enhancing the water compatibility of the various ingredients. The treatment is carried out by exposing the wood, while submerged in the treating solution, so one or more cycles of reduced pressure (i.e. vacuum) and elevated pressure.

Abstract: An improvement in a bowling lane having a decorative laminate surface which improvement comprises incorporating into the core of the laminate a plurality of alternating layers of glass cloth and crepe paper, each core layer being impregnated with a thermosetting resin and an organic fire retardant material, contiguous and adjacent core layers being interlaminarly bonded to one another.

Abstract: A substantial reduction of free excess formaldehyde in formaldehyde laden wood panels is achieved by coating at least one side of the panel with a salt solution containing an ammonium cation such as a 10-15% aqueous solution of ammonium bicarbonate. After coating, a barrier is placed over the coated surface such as by stacking a plurality of similarly coated panels with the barrier being maintained sufficiently long to allow ammonia gas generated from normal degradation of the ammonium salt to migrate to the free formaldehyde zone where the ammonia gas reacts with the formaldehyde to produce a stable, low volatility reaction product. The treatment may be applied to raw or finished panels and the generated ammonia gas reacts in the stacked panels with formaldehyde in both the glue lines and the formaldehyde based finish topcoating.

Abstract: Particulate resoles are produced by mixing phenol, formaldehyde and amine in an aqueous medium containing a protective colloid. The resoles exhibit improved cure rate and sinter resistance when an alkaline compound is added to the reaction mixture after particulate formation.

Abstract: Non-flammable reactive particle compositions useful in forming shaped articles prepared from flammable cellulosic materials and a type of urea/formaldehyde resin. Processes for their preparation and a method of rendering flammable reactive particles substantially inflammable.

Abstract: A lamina for a medium density structural board made from dimensioned wood flakes cut from a mixture of hardwood species and having a high retained internal bond strength is disclosed. The wood flakes are blended with a phenol formaldehyde resin having a major quantity of a low molecular weight fraction and a wax and then formed into a hot pressed product. The lamina may be used alone or as the core of a structural board having veneer, hardboard or plywood face panels. Three or more lamina may be formed into a structural board or used as the core of a board having veneer, hardboard or plywood face panels.

Abstract: The disclosed invention includes an improved construction of structural members such as railroad crossties, highway spin posts and highway guard posts and to construction of said members from composite wood material including elongated wood flakes and to a method for making such improved structures.

Abstract: An intumescent composition containing a cyclic nitrogen compound, a hydroxy-containing organo-phosphorus compound, an organo-phosphorus acid, and water, wherein:(a) said cyclic nitrogen compound is: ##STR1## wherein a, b, and c, are integers selected from the group consisting of 1 and 2, a plus b plus c equal about 3 to 6, and wherein and X, X', and X" are hydrogen or --CH.sub.3 ;(b) said hydroxy-containing organo-phosphorus compound is selected from the group consisting of: ##STR2## and mixtures thereof wherein R.sup.1, R.sup.2 and R.sup.3 are lower alkyl or haloalkyl radicals and R.sup.4 and R.sup.5 are hydrogen, lower alkyl or haloalkyl radicals;(c) said acid is selected from the group consisting of: ##STR3## and mixtures thereof, wherein R.sup.6, R.sup.7, R.sup.8 and R.sup.9 are hydrogen, lower alkyl, haloalkyl or hydroxyalkyl, R.sup.10 and R.sup.11 are lower alkyl, haloalkyl, hydroxy-polyalkyleneoxy, alkoxy, hydroxyalkoxy or haloalkoxy, ##STR4## wherein R.sup.

Abstract: A bowling lane having a decorative laminate surface in which the lane approach surface and the lane surface proper has a finish which provides a 60 degree gloss below about 30 in the machine direction as measured according to NEMA Standard 8-19-1964.

Abstract: A process for producing a filler for adhesive for bonding wood which comprises contacting a raw material of filler for adhesive composed of a vegetable cellulosic material with saturated steam or superheated steam and thereby heat-treating it.

Abstract: A urea-formaldehyde resin adhesive comprising a powder of a substance having the property of gradually reacting with an acid and thus consuming the acid.

Abstract: A combination railroad tie for supporting railroad track rails on a ballast or concrete roadbed. The main body portion of the tie is wood, having a rectangular cross section and a flat upper and lower surface. A plurality of flat plastic plies made of shredded wood fibers or wood chips bonded together by a thermal setting resin are, in turn, bonded to the upper and lower surfaces of the main body portion.

Abstract: A glue for wood, comprising a thermosetting condensation resin and a modified polyvinyl alcohol having a hydrophobic group in the side chain thereof.

Abstract: Co-condensates are prepared by condensing from 0.8 to 2.0 moles of butyraldehyde with 1 mole of a phenol at from 80.degree. to 220.degree. C. with the addition, before, during or after the condensation, of from 5 to 50% by weight, based on the mixture of phenol and butyraldehyde, of one or more thermoplastics containing functional groups, which reacts with phenol, butyraldehyde or the phenol-butyraldehyde resin under the condensation conditions. The co-condensates are used as hot-melt adhesives and as binders for nonwovens.

Abstract: A finished resin comprising a highly condensed phenol formaldehyde resole resin which has green groups formed by a low condensation phenol formaldehyde resin, the finished resin being modified by addition of a weak acid and a non-cellulosic protective colloid to improve reactivity and flow properties thereof.

Abstract: The strength of the bond obtained between substates with the aid of phenoplasts, modified phenoplasts and/or epoxy resins, e.g. between fibrous material and an elastomer on vulcanization thereof, is improved by applying, to at least one of the substrates, in addition to a preformed phenoplast, modified preformed phenoplast, and/or preformed epoxy resin, and drying thereon before the assembly thereof with the other substrate, as an adhesion promoter, a quantity of m-aminophenol, which may be blended in a phenoplast adhesive, such as an RF dip or an RFL dip, or may be blended in the elastomer latex used for forming an RFL dip. Adhesive/promoter blends and latex/promoter blends for forming the same are also disclosed.This is a divison of application Ser. No. 951,040, filed October 13, 1978, now abandoned, which in turn is a division of Ser. No. 754,182, filed December 29, 1976, now U.S. Pat. No. 4,131,584 which in turn is a division of Ser. No. 422,777, filed December 7, 1973, now U.S. Pat. No.

Abstract: An artificial lumber board comprises a plurality of elongated wood strips having medial body portions of different thicknesses and tapered tip end portions being thinner and more flexible than the medial portions wherein the wood strips are aligned longitudinally in the board and compressed. The compressed wood strips lap and bend over one another to form generally continuous sinuous wood grain-like structures extending along the board with the tapered tip portions providing generally point contact fitting of the wood strips with one another reducing the presence of void spaces in the board.

Abstract: Structural members having strength properties comparable or superior to those of solid wood are made from a composite wood material comprised of elongated wood flakes bonded together with a binder. The grain direction of the flakes extend generally parallel to their longitudinal axis and the flakes are oriented so that the longitudinal axis of at least a majority is generally parallel to the longitudinal axis of the structural member. The structural member is formed as a solid one-piece unit or assembled from two or more structural components which are made from the composite wood material and are joined together in angular relationship with an adhesive.

Abstract: Thermosetting water-immiscible phenol-formaldehyde resins in which a large proportion of the linkages between the benzene rings are benzyl ether linkages located ortho to the phenolic hydroxyl groups are produced by reaction of at least one mole of formaldehyde with 1 mole of phenol in an aqueous reaction medium in the presence of a metal carboxylate catalyst, such as, zinc acetate. Methods of control of the exothermic addition of formaldehyde to phenol are described.

Abstract: A stave for a tub has opposite elongate edges formed with formations each having a section transverse to the stave including an arcuate portion, and a rabbet for receiving a floor of the tub extending between the edges. The formations on each stave are desirably complementary, but need not be. Staves placed in edge-to-edge relation define a tub wall which can conform to an arbitrary shape and size. A tub is formed by a plurality of staves, an appropriately shaped floor, and bands extending around the outside of the tub wall.

Abstract: This invention relates to an improvement in a substrate web coated with a thermosetting coating resin and optionally impregnated with an aminoplast resin, in particular a web of paper, for the surface finishing of woodwork panels or laminates, the improvement that the coating resin is a modified polyester resin, composed of (a) 60 to 95% by weight of a hardenable polyester resin, (b) 1 to 15% by weight of a cross-linking agent for the polyester resin, (c) 5 to 40% by weight of a thermoplastic containing predominantly linear, high-molecular weight, reactive groups, (d) 1 to 15% by weight of a monomer with at least one polymerizable double bond and at least one group which reacts with the reactive group of the thermoplastic, and (e) a hardening catalyst, and optionally dyes, pigments and/or fillers. The invention also relates to a process for preparing a synthetic resin coated substrate web.

Abstract: A table or bench top provides a work surface of high strength that is resistant to impacts, high temperatures, alkalies, acids, flames, and electrical arcs. The top has a core composed of wood strips bonded together in side by side and end to end relation with thermosetting resins, a bottom particle board sheet and a top laminated fabric resin sheet cold bonded to the faces of the core, and side and edge wood finishing strips between the top and bottom sheets surrounding the core in bonded relation therewith. The finished top is especially useful as a work surface for welding, soldering, brazing, and has a high dielectric strength making it especially useful in the electronics industry.

Abstract: Composite products formed from at least one piece of wood and a resinated hydraulic cement and the method for their preparation are described. The predominantly mechanical bond between wood and hydraulic cement achieved by the prior art is significantly improved because of the presence of a thermoset resin in the cement such that adhesion occurs at the wood-cement interfaces by specific action of the resin, and a bond of greater integrity results. The cement and the resin function synergistically to consummate a bond with the wood wherein the resin performs the adhesion action and the cement performs a reactive filler or bulking action. The resulting composite products are stronger, more durable and can be made at lower densities than prior art products.

Abstract: A modified phenol-formaldehyde resin is formed by reacting phenol and formaldehyde in the presence of alkali and finely divided wood bark, preferably where the bark is pre-treated with alkali. The molar ratio of formaldehyde to phenol ranges from about 3 to 1.6. The molar ratio of alkali to phenol ranges from about 0.5 to about 1.0, said alkali being added to the formaldehyde-phenol mixture in three stages, each stage containing about one-third of the total alkali used. The amount of bark employed ranges from about 10 to about 40% of the amount of phenol. Adhesives prepared from these resins are suitable for use in the manufacture of plywood having both western mill and southern pine mill veneers.

Abstract: Phenolic novolak resins are produced from acetophenone, particularly by-product acetophenone obtained from the cumene process for manufacturing phenol, by the process of (1) reacting acetophenone with an aldehyde under alkaline conditions, and (2) reacting the product of step (1) with a phenol under acidic conditions. Phenolic resole resins are produced by reacting the product of step (2) with an aldehyde under alkaline conditions. The acetophenone modified phenolic resins are useful as a molding material, a felting or batting binder, a grinding stone binder, a foundry sand binder and an adhesive for timbers.

Abstract: A wood-bonding adhesive containing as the adhesive base sulfur and a synthetic thermosetting urea resin, phenol resin, melamine resin, resorcinol resin and a flame retardant mixture of compounds selected from styrene, maleic acid related materials, dicyclopentadiene and the like. Also, a method of adhesively bonding wood adherends together and an article bonded by the adhesive are disclosed.

Abstract: A new and improved, high quality, bark-extended phenolic resin adhesive composition for bonding wood plies, particularly southern mill wood such as the southern pine, comprising the reaction product of finely ground wood bark particles treated with a caustic solution and a low molecular weight, aqueous alkaline phenol-aldehyde resin. The resin has a low degree of polymerization and is soluble in all proportions in ethanol. The resulting adhesive has a proportion by weight of total resin solids in the range of approximately 25.1% to 20.9% and a proportion of total solids in a range of approximately 40% to 40.85% based upon the total weight of the adhesive composition. The adhesive has a viscosity in a range of approximately 9,000 centipoise to 10,600 centipoise.

Abstract: A process for making a phenol-aldehyde resin adhesive is disclosed in which a portion of the phenol ingredient is replaced with ammonium lignosulfonate. Solid ammonia base waste sulfite liquor residue is dissolved or suspended in phenol and the mixture is heated to a temperature range of 150.degree.-300.degree. C under autogenous pressure until the resulting phenol-ammonium lignosulfonate component of the reaction mass is water insoluble but soluble in aqueous sodium hydroxide. The reaction mass may be washed with water to remove soluble wood sugars and their derivatives. The phenol-ammonium lignosulfonate component may then be condensed with an aldehyde resulting in a resin product that is useful as an exterior adhesive, having suitable water insolubility and adhesive characteristics. The ratio of ammonium lignosulfonate to phenol may range from 2:1 to 1:10, depending upon the desired properties of the finished adhesive.

Abstract: An elongated board of artificial lumber having a length greater than the width and thickness comprising a mixture of irregularly shaped elongated splinters of wood substantially aligned along the length of the board; a substantial portion of the mixture including splinters from about 2" to 10" long; a sealant coating the surface of the splinters; an adhesive carried on the splinters with the sealant restricting the penetration of the adhesive into the splinters so as to produce hardened layers between the splinters for holding the splinters in an interlocking configuration.

Abstract: Bark-extended tannin-aldehyde resinous adhesives are formed in situ as adhesives for wood products, such as plywood. Bark, in a finely divided particle form, is treated with alkali and then used as an extender by admixing the bark particles with tannin and an aldehyde co-reactant therefor. The admixture is combined as a bonding agent for the wood members to be adhered, and is formed in situ into an adhesive by subjecting the wood members to temperature and pressure conditions effective to form a bark-tannin-aldehyde resin.

Abstract: A method of producing dry-process composition paper board from waste paper. Waste paper is particulated into flakes and the like fragments, conditioned for moisture content, and blended with an adhesive such as a synthetic thermosetting resin prior to forming by compression into mats which are cured under high pressure and temperature to form a rigid, cohesive paper flake board.The method obviates the need of sorting, pulping, cleaning and purification of waste paper and permits manufacture of structural panel boards in small recycling plants.

Abstract: A plywood body is disclosed which comprises at least two plies of wood bonded together with a phenolic resin adhesive having platey talc incorporated therethrough in amounts of about 5 to 200 parts by weight per 100 parts by weight of resin. Such plywood bodies (particularly boards) have significantly greater fire resistance than do plywood bodies containing conventional phenolic adhesives.

Abstract: A decoratively branded plasterboard product having a pattern of recesses formed in the paper-like outer surface of the plasterboard is disclosed. The recesses are charred to discolor the same, and the pattern is preferably a wood grain simulating pattern.

Abstract: A method for accelerated curing of phenolic resin adhesives comprises adding powdered green tea to a thermosetting phenolic resin at about ambient temperature.