Patent ID: 8840820
Filing Date: 2014-09-23
Classification: B05C,B29C,C08J,Y10T

Abstract:
1. A method for producing an oriented strand board from cellulosic particles and an exterior resin binder, the method comprising the steps of: mechanically foaming a phenol formaldehyde exterior resin binder to produce an uncured foam using a foaming device configured to agitate liquid resin with gas, wherein the phenol formaldehyde binder is an aqueous resole having a pH level greater than about 7.0 and a formaldehyde/phenol molar ratio greater than about 1.0, and wherein foaming the phenol formaldehyde binder to produce the foam further comprises blending the phenol formaldehyde binder and a surfactant for mechanical foam stabilization, the surfactant being selected from the group consisting of anionic, amphoteric, and nonionic surfactants; tumbling the cellulosic particles in a rotary blender; applying the uncured foam made in the foaming device to the cellulosic particles in the rotary blender; blending the cellulosic particles and the uncured foam so that the foam substantially covers the cellulosic particles; and consolidating the cellulosic particles and curing the uncured foam using heat and pressure in a pressing device, wherein the pH of the uncured foam in the consolidation process is greater than about 7.0.