IMPROVED SHEETING MATERIAL AND METHOD OF MANUFACTURING THE SAME

Abstract: Sheeting in the form of fibre board comprising cellulose fibres and a thermosetting resin in an amount sufficient to bond the cellulose fibres together when compressed the sheeting having a density of 1100 kg/m<3> or greater. The method of manufacturing the sheeting comprises the steps of combining the cellulose fibres and thermosetting resin together and forming a mat or web, and thereafter heating and compressing the mat or web to a density of at least 1100 kg/m<3>.

Description: "IMPROVED SHEETING MATERIAL AND METH O D OF MANUFACTURING THE SAME" This invention relates to an improved sheeting materia and method of manufacturing the same. One type of sheeting material currently known is forme from a b lend of wood fibre and resin materia l whic h i compressed to form a sheet. An example of such sheeting, i sol d un d er the Trade Mark Laminex Craftwood. This s h eetin finds application in the manufacture of furniture and wal paneling such as for cupboards and the like. Typica sheeting of this type has resin content in the order o f 7 to 9% by weight and a density of 700 kg/m 3 . The major d isadvantage of sheeting of this type is that it has relatively low strength and is prone to degradation such as swelling or other deformation as a result of exposure to moisture. Another type of sheeting currently in use is formed from a series of paper plies with resin material interpose d or mixed therewith and thereafter compressed to form a sheet. T his sheeting is far stronger than the wood fibre sheeting described above, and is also not as susceptible to d egra d at i on as a result of exposure to moisture. An example of such sheeting is sold under the Trade Mark Laminex Solid Grade. The major disadvantage of this sheeting is its relatively high cost to manufacture. i t is an object in accordance with one aspect of the present invention to provide an improved sheeting which is relatively cheap to manufacture but has relatively high strength and is resistant to degradation as a result of exposure to moisture. it is also an object in accordance with another aspect of the present invention to provide a method of manufacturing sheeting. According to one aspect of the present invention there is provided sheeting comprising cellulose fibres and a thermosetting resin in an amount sufficient to b on d the cellulose fibres together when compressed characterized in SUBSTITUTE SHEET that the sheeting has a density of 1100kg/m 3 or greater. According to another aspect of the present invention there is provided a method of manufacturing sheeting comprising the steps of combining cellulose fibres and a thermosetting resin together and forming a mat or web, and heating and compressing the mat or web to a density of at least 1100 kg/m 3 . Desirably the cellulose fibres and thermosetting resin are compressed beyond a point where the gradient of a line measuring the internal bond strength of the sheeting on the abscissa against the density of the sheeting on the mantissa changes, the gradient of the line being steeper beyond the aforementioned point. It has been surprisingly found that the properties of sheeting comprising cellulose fibre and resin can be markedly improved by increasing the density of the sheet formed beyond a particular level which, to some extent, is dependent upon the amount of resin used. The reason for the unexpected improvement in properties of the sheet is not understood. It can be speculated that as the composition is compressed the voids between the fibre and resin become increasingly small. It is these voids which allow ingress of water which cause the degradation of the currently known fibre board of the type referred to earlier in damp conditions. As the voids become increasingly smaller the water molecules find it increasingly difficult to permeate the board. This increase in difficulty has been found to be approximately linear with increase in density. However, at a certain stage of compression some of the voids become too small to allow the water molecules to pass. At this stage these small voids are effectively acting as a filter to prevent ingress of water. It is believed that f urt h er increase in density beyond this point decreases permeability at a higher rate as the proportion of voids below the critical size increases until all voids are below the critical size and the properties of the sheeting reach a plateau based on the nature of the resin/fibre composition being used. HE 1 It has been found by experimentation that the point 2 inflection of the internal bond/density curve 3 approximately reached when the swelling in water of t 4 sheet i s less than 1%. The test for swelling in water 5 conducted in accordance with British Standard BS 5669 t 6 d urat i on of i mmersion being 24 hours. hilst not w i s hi ng 7 be b oun d b y this theory, it is believe d t h at t h is wat 8 absorbency level is the point when a significant number the voids in the composition have been squeezed to a s i less than the critical size to allow permeation of wat molecules. The critical point is reached at different densiti depending upon the proportions and nature of the resin use in the fibre/resin mixture. At high proportions of resin say 25% resin, the point is reached at a density o 1100kg/m3 or less and at very low proportions of resin, sa 5% the point is reached at very high densities of 1600kg/m or more. The cost of resin is an order of magnitu d e greater tha the cost of fibre and hence there is an optimum proportio of resin to fibre based on the balance between extra cost of resin and the extra material cost and processing cost o producing the same volume of a higher density board. The temperature required during the process is dependent on the resin being used and suitable temperatures are well known to those skilled in the art. The thermosetting resin may be present in an amount such that when the sheeting is subjected to a water absorption test in accordance with British Standard BS 5664 the immersion time for the test being 24 hours, the water a b sorption of the sheeting is less than 1%. The thermosetting resin may be present in an amount of at least 15% by weight and desirably in an amount in the range of 15% to 25% by weight. A particularly suitable amount is about 16% by weight. The percentage of resin or res.l n lnarl-n . ,..».-_ __ res.n load i ng referred to is calculated on a dry solids bbaassiiss. That is 16% resin by weight means 16% by weight of resin to dry fibre weight. The sheeting in its final for™ may also contain water in an amount in the range of 4% to 11% by weight. To achieve the required density of the sheet material according to the present invention, it is subject to a pressure of up to 1800psi and preferably, about 1500 psi. The pressure used is not particularly critical. It has been found that normally a pressure of at least 1500 psi is required to obtain a density of 1100 kg/m 3 . N ormally available commercial presses are unable to be used above 2000 psi. The exact pressure to be used to obtain a sheet of the required density and water swell may be f oun d for any particular composition of fibre and resin by simple experiment. The nature of the cellulose fibre used is not narrowly critical. Suitable fibre may be vegetable fibre such as for example bagasse. The cellulose fibres may be in the form of wood fibres and while many types of wood fibre may be suitable pinus radiata have been found particularly useful. Any resin suitable for use in forming sheeting from fibrous material may be used. Advantageously, resins of the amino resin type are used arid it is desirable that the resins include a phenolic component such as phenol, tannin or recorcinol. Such resins which are suitable for use in the sheet i ng of the invention include Melamine Urea Phenol Formaldehyde ( MUPF), Melamine Phenol Formaldehyde ( MPF ) , Melamine Urea Formaldehyde ' (MUF), Tannin Formaldehyde ( TF ) Phenol Urea Formaldehyde (PUF) and Recorcinol Urea Formaldehyde ( RUF). It has been found that an amount of resin included in the material in the region of about 16% by weight is particularly advantageous. The press may be heated and the combination of heat and pressure cures the resin so as to thereby produce the sheeting. T O assist in understanding the present invention reference is made to the attached drawings in which:- Figure 1 is a graph plotting the internal bond strength of sheeting against the density for sheeting containing the same amount of resin; and SUBSTITUTE SHEET Figure 2 is a graph plotting the percentage modulus of rupture retention against density of sheeting after 72 hours boiling. The two graphs shown in Figures 1 and 2 resulted from trials conducted to test sheeting compressed to various densities . In Figure 1, a series of sheets were produced of different densities but with the same amount of resin. The fibrous material was in the form of pinus radiata wood fibre and the resin was an amino resin with a phenolic component. The fibre and resin was formed into a mat with a moisture content of between 8% to 15% before compressing. The mat was compressed in a pressure at a suitable temperature to form a 16mm board using sufficient amount of material to achieve the desired density. The graph represents the line of best fit resulting from the trials conducted. As can be seen, the internal bond for the various sheets increases generally linearly as the density increases up to a value of about 1100 kg/m 3 . At densities about this critical level, however, the rate of increase in internal bond strength increases markedly. In Figure 2 four lines are shown, being typical plots for sheets containing between 10% to 25% resin by weight. In this case, the percentage modulus of rupture retention after 24 hours boiling is the characteristic being plotted. This test was done in accordance with Australian Standard AS 1859. Again the graph shows a change in rate of improvement in the property in the region of density of around 1100 kg/m 3 . The sheeting is most advantageously formed in a process line and an example of such line is set out below. Logs of timber from which the wood fibre is to be produced are first debarked and then passed through a chipper which reduces the timber into small chips. After chipping, chips may be transferred to a chip pile prior to being washed to remove any grit and other waste material which would damage machinery used in subsequent processing steps. The clean chips may be conveyed to a steamed digester unit where the chips are heated by steam in order to soften or plasticise them. This process allows easier break down of the chips into fibre as well as providing improved fibre quality. The chips enter the defibrator which rubs the wood apart into fibres. The newly formed fibre may be conveyed to dryer units and at this stage, the wet fibres may be sprayed with resin. after drying, the fibres may be placed in a dry fibre storage bin before being conveyed to a forming machine. The forming machine may be adapted to lay the fibre into a mat of random orientation by way of vacuum system drawing that fibres is down onto a mesh belt. The mat is preferably laid continuously and passes from the forming machine at a selected height. A precompressor may be used to reduce the thickness the mat prior to entering the press. Preferably the mat is trimmed to pressing with and cut to board length by a flying cut off saw. The mat may pass through a density cage which checks for profile consistency. A metal detector may be provided to scan the mat for foreign bodies. The mat may pass into a loading cage before entering a press which produce the sheeting according to the invention and which in a preferred form is heated by oil so that the combination of heat and pressure cures the resin and produces the sheeting. If desired, the sheeting so formed can have laminated paper or other, secured to the external surface thereof. It has been found that the sheeting material of the present invention exhibits properties for superior to standard sheeting formed from wood fibre and resin and that the properties are comparable to those of sheeting material formed from paper plus and resin. Finally, it is to be. understood that various alterations, modifications and/or additions may be incorporated into the various constructions and arrangements of parts without departing from the spirit and ambit of the invention. SUBSTITUTE SHEET

Claims: CLAIMS 1. Sheeting comprising cellulose fi b res and thermosetting resin in an amount sufficient to bond t cellulose fibres together when compressed characterized that the sheeting has a density of 1100kg/m 3 or greater. 2. Sheeting according to claim 1 characterized in th said thermosetting resin is present in an amount such th when the sheeting is subjected to a water swell test accordance with British Standard BS 5669, the immersion ti f or t h e test- being 24 hours, the water swel l ing o f t h sheeting is less than 1%. 3. S heeting according to claim 1 or claim 2 wherein sai thermosetting resin is present in an amount of at least 10 by weight. 4. Sheeting according to claim 1, 2 or 3 wherein sai thermosetting resin is present in an amount of at least 15 by weight. 5. Sheeting according to any preceding claim wherein sai t h ermosett i ng is present in an amount in t h e range of 15% t 25% by weight. 6. Sheeting according to any preceding claim wherein sai thermosetting resin is present in an amount of about 16% b weight. 7. Sh eeting according to any preceding claim wherein the sheeting contains water in an amount in the range of 7% to 11% by weight. 8. Sheeting according to any preceding claim wherein said cellulose fibre is wood fibre. 9. Sheeting according to any one of the preceding claims wherein the density of the sheeting is in the range of HOOkg/m 3 to 1300 kg/m 3 . 10. A method of manufacturing sheeting comprising the steps of combining cellulose fibres and a thermosetting resin together and forming a mat or web, heating and compressing the mat or web to a density of at least 1100 kg/m . 11. A method according to claim 10 wherein the cellulose fibres and thermosetting resin are compressed beyond a point where the gradient of a line measuring the internal bond strength on- the abscissa against the density on the mantissa of the sheeting changes, the gradient of the line being steeper beyond said point. 12. A method according to claim 10 or claim 11 wherein said thermosetting resin is present in an amount of at least 10% by weight. 13. A method according to any one of claims 10, 11 or 12 wherein said thermosetting resin is present in an amount of at least 15% by weight. 14. A method according to any one of claims 10 to 13 wherein said thermosettin is present in an amount in the range of 15% to 25% by weight. 15. A method according to any one of claims 10 to 14 wherein said thermosetting resin is present in an amount of about 16% by weight. 16. A method according to any one of claims 10 to 15 wherein the sheeting contains water in the range of 7% to 11% by weight. 17. A method according to any one of claims 10 to 16 wherein said cellulose fibre is wood fibre. SHEET

Inventors: ANTHONY PATRICK LYLE, ANTHONY, PATRICK, LYLE
Applicants: A C I INT LTD, ACI INTERNATIONAL LIMITED
Application year: 1990
Main classification: B27N3
IPC codes: B27N1, B27N3, C08L97