Abstract:
A composite board having a  sorghum  stalk material component and a binder component is disclosed together with a corresponding method of manufacture. To prepare the composite board, the  sorghum  stalk material is harvested, dried and refined into fibers. The fibers are then combined with a binder such as a thermosetting resin. The resin coated fibers are then arranged into a stack having several layers. Within each layer, the resin coated fibers are aligned along a predetermined layer axis. Next, the stack is thermocompressed in a press at a preselected temperature to compress the resin coated fibers to a preselected board thickness.

Description:
[0001]    This application claims priority to provisional U.S. patent application No. 61/544,856 filed Oct. 7, 2011 titled “Oriented Strand Boards made with  Sorghum  Stalks and Processes for Making Same.” This application is related to provisional U.S. patent application No. 61/544,884 filed Oct. 7, 2011 titled “Composite Boards made with  Sorghum  Stalks and a Thermoplastic Binder and Processes for making same.” The entire contents of provisional application 61/544,856 and provisional application 61/544,884 are hereby incorporated by reference herein. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention pertains generally to composite boards. More particularly, the present invention pertains to composite boards having oriented agrifiber strands. The present invention is particularly, but not exclusively, useful as an oriented  sorghum  strand board (OSSB) made from  sorghum  stalk material and a binder. 
       BACKGROUND OF THE INVENTION 
       [0003]      Sorghum  is a genus of numerous species of coarse, upright growing grasses having stalks ranging in the length from about 5-15 feet long.  Sorghum  can be grown under a wide range of soil and climatic conditions including arid areas where crops such as corn would require substantial irrigation. The primary cultivated species,  sorghum  bicolor, grows well in hot, arid climates, making it popular with subsistence farmers. 
         [0004]    In addition to the classification of  Sorghum  into species, the  sorghum  species and hybrids are often classified into  sorghum  types. Types include grain  sorghum , forage  sorghum , Sudangrass which is a subspecies of  sorghum  bicolor and  Sorghum -sudangrass hybrids (which are a cross between the two forage type  sorghums ) and  Sorghum -almum. Forage  Sorghums  includes sorgo, sweet  sorghum , dual purpose (grain and forage) varieties, and hybrids. Sweet  sorghum  and forage  sorghum  hybrids are often used for ethanol production and are sometimes referred to as energy  sorghums . As provided further below, the stalks of so-called energy  sorghums  may be particularly suitable for use in making composite boards such as OSB due to their superior strength and properties. 
         [0005]      Sorghum  is used for both grain and fodder production and has been identified as a possible source of ethanol as it provides high biomass yield with much lower irrigation and fertilizer requirements than corn. Grain  sorghum  is grown in the United States, Mexico, India, and throughout Africa and South Asia. It is considered the fifth most important cereal crop in the world. Notably,  sorghum  straw is a rapidly renewable resource—it can grow more than 2 m (6 ft) tall in a single season. Similar wood growth can take many years.  Sorghum  stalks are far thicker and more substantial than wheat or rice straw, allowing for better engineering of the product. The center of a  sorghum  stalk is far less dense than the hard outer ring, so the material can be compressed to different degrees. The  sorghum  crop is frequently grown using less fertilizers and pesticides than other grains, the material is low in chemical residues. As an added benefit, it is naturally resistant to many types of fungi and insects. 
         [0006]      Sorghum  stalks and  sorghum  stalk bagasse (the stalk material remaining after juice extraction for ethanol production) are currently used for thatch, fences, baskets, brushes, paper and cattle fodder. However, the supply of  Sorghum  stalks and  sorghum  stalk bagasse greatly exceeds demand, and as a consequence, a large amount of this material is either plowed under or burned. Specifically, in many parts of the world, the straw is burned in the field. After harvest time, the burning can be so plentiful that the skies darken with soot. Traveling miles across the landscape, the resulting smoke plumes are so thick they can be seen in photos taken from outer space. It not only pollutes the air, but emits greenhouse gases (GHGs) linked to the current climate crisis. 
         [0007]    Utilizing agricultural waste diverts it from this process, eliminating a source of GHGs and large-particle air pollution. Another green aspect of using waste stalks such as  Sorghum  as a raw material is the embedded energy to produce agrifiber panels is less than with wood panels. In making both composite wood and agrifiber boards, moisture inside cells or between them must be removed for proper penetration of binder. Agrifibers generally have larger cellulose cells than wood, so the cell wall is softer and thinner, and moisture removal requires less energy. 
         [0008]    The cellulose of agrifiber cell walls such as  Sorghum  is more easily penetrated by chemicals than similar structures in wood fiber, making modifications to improve material properties more effective. For example, agents such as acetyls (commonly used in engineered wood panels to improve dimensional stability, moisture resistance, and strength) are more effective when treating agrifiber stalks such as  Sorghum . Ease of cell penetration in agrifiber such as  Sorghum  stalk material also makes it more likely than wood to accept new green binders such as soybean protein, modified flour pastes, or even recycled thermosetting plastics. 
         [0009]    Agrifiber board based on  sorghum  straw (i.e.  sorghum  stalks) offers an environmentally responsible product useful as a direct substitute for commercially available wood based particleboard, wood based medium-density fiberboard (MDF), plywood and wood based oriented strand board (OSB). In performance, environmental impact, and cost, it is comparable to or better than those wood-based products, and unlike many of them, can be formulated to emit neither formaldehyde nor volatile organic compounds (VOCs). Moreover, the nature of the  sorghum  stalk makes it a better fiber for construction than many other agrifiber materials. 
         [0010]    Traditional wood-based oriented strand board (OSB) also known as waferboard, Sterling board, Exterior board and SmartPly is a structural wood composite formed by layering strands (flakes) of wood in specific orientations. 
         [0011]    Traditional wood-based oriented strand board (OSB) is a mat-formed panel made of wood strands, also called flakes, sliced in the long direction from small diameter, fast growing round wood logs, such as freshly harvested aspen poplar, southern yellow pine or other mixed hardwood and softwood logs, and bonded with an exterior-type binder under heat and pressure. 
         [0012]    Traditional wood-based OSB is typically manufactured by layering wood strands ranging in length from about 3½″ to 6″ and approximately 1″ wide. The strands are coated with wax and resin binders (95% wood, 5% wax and resin) and then compressed and bonded together in a thermal press. Layers are created by shredding the wood into strips, which are sifted and then oriented, for example, using belts or wire cauls. Generally, the layers are built up with the external layers aligned in the panel&#39;s strength axis with internal layers cross-oriented. The finished product has similar properties to plywood, but is cheaper and more uniform. 
         [0013]    Binders used to produce traditional wood-based OSB panels include thermosetting plastic resins such as urea formaldehyde (UF), phenolic resins such as phenol formaldehyde (PF) and formaldehyde-free, isocyanate resins such as polymeric methylene diphenyl diisocyanate (PMDI). 
         [0014]    Products such as traditional wood-based OSB made with resins such as UF and PF which release formaldehyde and other volatile organic compounds (VOC&#39;s) over the life of the product may be hazardous as formaldehyde is a known carcinogen and formaldehyde emissions have been linked to respiratory illness, asthma and premature death, especially for children and the elderly. 
         [0015]    As used herein, formaldehyde-free binder means that the binder does not contain non-trace amounts of formaldehyde or materials that release formaldehyde during the life of the product. 
         [0016]    As used herein, the term “Volatile organic compound” means materials having organic chemicals that have a high vapor pressure at ordinary, room-temperature conditions. Their high vapor pressure results from a low boiling point, which causes large numbers of molecules to evaporate from the liquid or solid form of the compound and enter the surrounding air. An example is formaldehyde, with a boiling point of −19° C. (−2° F.), slowly exiting paint and getting into the air. The term “zero VOC” means a material having zero detectable VOC&#39;s using standard detection equipment. 
         [0017]    Traditional wood-based OSB is suitable as a structural panel for a wide range of construction and industrial applications. The most common uses of traditional OSB include sheathing in walls, floors, and roofs. Panels are available in nominal 4′×8′ sheets (1220×2440 mm) or larger, and thicknesses of ¼″, ⅜″, 7/16″, 15/32″, 19/32″, 23/32″, ⅞″, 1⅛″ and 1¼″. OSB is also used extensively for the webs of prefabricated wood Hoists and in structural insulated panels (SIPS), also known as foam-core sandwich panels. Property specifications for a typical traditional wood-based 0513 (CSA O437; Grade O-2) include minimum modulus of rupture, parallel (29.0 MPa) perpendicular (12.4 MPa); minimum modulus of elasticity, parallel (5500 MPa), perpendicular (1500 MPa); minimum internal bond (0.345 MPa); maximum linear expansion, oven dry to saturated, 0.35% parallel, 0.50% perpendicular; maximum thickness swell, 15% for ½″ thick or less, 10% for greater than ½″; Minimum lateral nail resistance of 70t N, where t=thickness in millimeters. 
         [0018]    Properties of Wood-Base Fiber, Agrifiber and Particle Panel may be tested in accordance with ASTM D 1037-99. These properties can include Moisture Absorption, Thickness Swelling, Volume Swelling and Linear Expansion. 
         [0019]    The modulus of rupture (MOR) and modulus of elasticity (MOE) can be determined by a static, three point bending test in accordance with ASTM D 1037-99. The internal bond strength (IB) can be determined by testing tensile strength perpendicular to the OSB surface in accordance with ASTM D 1037-99. 
         [0020]    Other Test standards suitable for Evaluating Properties of Wood-Base. Fiber, Agrifiber and Particle Panel include; 
         [0000]    
       
         
               
               
             
           
               
                   
               
               
                 Test Standard 
                 Physical Property to be Established 
               
               
                   
               
             
             
               
                 USFPL 1344 
                 Mold Resistance 
               
               
                 ASTM E-661 Method A 
                 Concentrated Impact Load resistance 
               
               
                 ASTM D-1761/1037 
                 Fastener Holding Performance 
               
               
                 ASTM D-3043 Method C 
                 Panel Bending Strength and Stiffness 
               
               
                 ASTM D-3501 Method B 
                 Panel Compression Properties 
               
               
                 ASTM D-1037: 
                 Linear Expansion - Humidity Change 
               
               
                   
                 (108-111) 
               
               
                 ASTM D-1037: 
                 Strength Properties: Static Bending 
               
               
                   
                 (11-20) 
               
               
                 ASTM D-1037: 
                 Tensile Strength Parallel to Surface 
               
               
                   
                 (21-27) 
               
               
                 ASTM D-1037: 
                 Tensile Strength Perpendicular to Surface 
               
               
                   
                 (28-33) 
               
               
                 ASTM D-1037: 
                 Direct Screw Withdrawal Test (61-67) 
               
               
                 ASTM D-1037: 
                 Abrasion Resistance by the U.S. Navy Wear 
               
               
                   
                 Tester (96-99) 
               
               
                 ASTM D-1037 
                 Linear Variation with Change in Moisture 
               
               
                   
                 Content (108-111) 
               
               
                 ASTM D-1037: 
                 Interlaminar Shear (122-129) 
               
               
                   
               
             
          
         
       
     
         [0021]    Test methods for Evaluating Formaldehyde Emission and Content Properties of Wood-Base Fiber, agrifiber and Particle Panel include; 
         [0022]    Large Chamber (ASTM E1333) 
         [0023]    Desiccator (ASTM D5582) 
         [0024]    Small Chamber (ASTM D6007) 
         [0025]    Japanese 24 Hour Desiccator (JIS A1460) 
         [0026]    Perforator (EN 120), Single Extraction 
         [0027]    Perforator (EN 120), Duplicate Extraction 
         [0028]    Unless otherwise specified, all test results reported herein were conducted using the test methods provided above. 
         [0029]    In light of the above, it is an object of the present invention to provide oriented  sorghum  strand board that is made from materials having a relatively low adverse environmental impact. Still another object of the present invention is to provide formaldehyde-free oriented  sorghum  strand board containing substantially zero VOC&#39;s. Yet another object of the present invention is to provide oriented  sorghum  strand boards that are made with  sorghum  stalks and processes for making same which are easy to use, relatively simple to implement, and comparatively cost effective. 
       SUMMARY OF THE INVENTION 
       [0030]    For the present invention, a composite board is disclosed which includes a  sorghum  stalk material component and a binder component. To prepare the composite board, the  sorghum  stalk material is first harvested. The  sorghum  stalk material can include  sorghum  stalk bagasse (the stalk material remaining after juice extraction for ethanol production) and/or  Sorghum  stalks. In one particular implementation, stalk material from energy  sorghums  such as sweet  sorghum  and forage  sorghum  hybrids are used. In one implementation, the  sorghum  stalk material is harvested using a mower/conditioner. In this process,  sorghum  stalks and first cut (i.e. mowed) at or near their base and conditioned by crimping the stalks every 12 to 18 inches along their length to crack open the epidermis to allow the stalk to air dry at the harvest site. 
         [0031]    In some cases, mechanical or chemical processing may be used to remove or peel the waxy outer coating from the stalk material. The stalks may be dried naturally or dried using an industrial dryer to a moisture content of less than about 10% by weight, and more typically, to a moisture content in the range of 7.5 to 9.0%. 
         [0032]    The stalk material can then be mechanically processed (either before or after drying) in stalk segments, for example by cutting or breaking the stalk material. Typically, the step involves segmenting stalk material having an initial length of about 8 to 14 feet into segments having a length in the range of about 4 to 20 inches, and more typically in the range of about 4 to 6 inches. After the stalk material has been cut to length, the stalk segments can be refined can reduce the fiber size and split grain  sorghum . For this purpose, a mill such as a disc mill may be used. For example, a disc mill have a mill gap set at 0.3 inch can be used. 
         [0033]    After cutting and/or milling, the stalks and/or stalk segments may be filtered, screened or cleaned at various times during the process to remove fines, etc. For example, in one implementation, the  sorghum  is refined and then screened to remove small particles (i.e. fines), leaves, and epidermis. For example, an oscillating screener having two screens, a top screen with 20 mm openings and a bottom screen size with 5 mm openings can be used. In some implementations, the stalks may be softened, for example by water soaking or steaming. 
         [0034]    The stalk segments may be mixed with small amounts, e.g. less than 5% by weight, of other fibrous or non-fibrous materials such as wood, other  sorghum  plant portions, corn plant portions, sugar plant portions, etc. 
         [0035]    The dried  sorghum  stalk material is combined with a binder such as a thermosetting resin. For example, the binder may be sprayed using nozzles onto the  sorghum  stalk material or may be applied in a tumbler. Other techniques include curtain coating, roller coating and dipping. 
         [0036]    In one aspect, a formaldehyde-free, isocyanate resin such as polymeric methylene diphenyl diisocyanate (PMDI) may be used. For example a PMDI resin such Rubinate 1840 sold by Huntsman. A suitable mix ratio of MIDI to stalk material is about 2.7-6.5% by weight of PMDI and about 93.5-97.3% by weight stalk material. In one implementation, a mix ratio of PMDI to stalk material is 3-5% by weight of PMDI and 95-97% by weight stalk material is employed with a target of about 4% by weight of PMDI and about 96% by weight stalk material. 
         [0037]    In another aspect, a formaldehyde-free protein based resin may be used. For example, the protein based resin can consist of a soy protein based resin, a canola protein based resin, a castor protein based resin, jatropha protein based resin or a combination of different protein based resins. 
         [0038]    A suitable mix ratio of protein based resin to stalk material is 4-12% by weight of protein based resin and 88-96% by weight stalk material. In one implementation, a mix ratio of protein based resin to stalk material is 7-9% by weight of protein based resin and 91-93% by weight stalk material is employed with a target of about 8% by weight of protein based resin and about 92% by weight stalk material. 
         [0039]    In another aspect, the binder can include a combination of PMD and a protein based resin. 
         [0040]    Once coated, the binder coated  sorghum  stalk material can be oriented and layered. A typical pre-compressing layer depth in the range of about 4 to 5 inches may be used, with each layer oriented orthogonal to adjacent layers. Layers may be stacked directly on a release coated press platen or the layers may be stacked and then placed onto the platen. A single layer or multiple layers may be used. In one aspect, at least three layers are used. In another aspect, an odd number of layers are used. One or more layers may have stalk material randomly oriented. In one aspect, exterior layers are aligned in parallel. In one aspect, each layer is oriented substantially orthogonal to adjacent layers in the stack. Typically, in each layer, the stalk material is oriented along a layer axis such that at least 90% of said  sorghum  stalk material is aligned within +/−45 degrees of the layer axis. In some implementations, the stalk material may be combined with binder after orienting and/or layering. In one implementation, one or both of the boards surface layers include 20 to 30 percent by weight of  sorghum  fines to improve surface finish (i.e. to reduce surface roughness). 
         [0041]    The stack of layer(s) is then thermocompressed in a press between heated flat platens. One or more thermocompressions may be employed. Various press temperatures, pressures and durations may be employed depending on the desired board thickness and board density. Typically, thickness and density are specified, and the layer/stack input thickness and press pressure are varied, to obtain the desired final thickness and density. Typically, a precompressed layer thickness of about 4-5 inches will compress to about ½ inch. After pressing, the board may be trimmed. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0042]    The novel features of this invention, as well as the invention itself, both as to its structure and its operation, will be best understood from the accompanying drawings, taken in conjunction with the accompanying description, in which similar reference characters refer to similar parts, and in which: 
           [0043]      FIG. 1  is a process flow chart showing steps for preparing an oriented  sorghum  strand board containing  sorghum  stalk material and a binder; 
           [0044]      FIG. 2  is a perspective view showing a fin/frame assembly for orienting and layering binder coated  sorghum  stalk material; 
           [0045]      FIG. 3  is an isometric view of a stack of binder coated  sorghum  stalk material having three layers, with each layer oriented orthogonal to adjacent layers; 
           [0046]      FIG. 4  is a front plan view of a stack of binder coated  sorghum  stalk material having three layers positioned between release coated press platens; 
           [0047]      FIG. 5  shows a plot of mat pressure (psi) and board thickness (in.) versus time for a thickness controlled press regimen to produce a board having a final desired thickness of about 0.55 inches; 
           [0048]      FIG. 6  shows a board after pressing; 
           [0049]      FIG. 7  shows the board after trimming; and 
           [0050]      FIGS. 8-13  show density modified properties for one layer and three layer boards. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0051]      FIG. 1  shows a process for preparing an oriented  sorghum  strand board containing  sorghum  stalk material and a binder. Uses of OSSB boards containing  sorghum  stalk material described herein can include, but are not necessarily limited, to structural panels designed for exterior use in construction and industrial applications such as sheathing in walls, floors, and roofs, for the webs of prefabricated wood I-joists and in structural insulated panels (SIPS), also known as foam-core sandwich panels. As shown in  FIG. 1 , the process begins by preparing  sorghum  stalk portions (box  10 ). More specifically, the  sorghum  stalk portions can be prepared as described above by stalk harvesting, conditioning, drying, refining and screening. Once prepared, the  sorghum  stalk portions are combined with binder (box  11 ), as described above. As indicated above, the binder may include a thermosetting resin such as PMDI and/or a protein based resin such as a soy protein based resin. When used, the soy protein based resin may be produced from soy meal/flour, soy protein concentrate or soy protein isolate. The soy protein based resin may be self-crosslinking or used with a cross linker. The soy protein based resin may be in alkaline form or as a slightly acidic dispersion. For example, the preparation of a soy protein resin having a slightly acidic dispersion can include denaturation of soy flour to expose groups for reaction and adhesion, introduction of viscosity/performance stability; modification and stabilization, for example with CH 2 O 2 , copolymerization, for example with PMDI; and inversion with acid addition. The soy protein based resin may be denatured and copolymerized with small amounts of reactant to produce a product that is biologically stable. 
         [0052]    The soy protein based resin may be, for example, Soyad adhesive product # D-40999 and cross-linker product # D-40767 containing 1,3-dichloropropan-2-ol (1,3-DCP), available from Heartland Resource Technologies, LLC—Ashland. The properties of each are listed in the table below. 
         [0000]    
       
         
               
               
               
             
               
               
               
               
             
           
               
                   
                   
               
               
                   
                 D-40999 
                 D-40787 
               
               
                   
                 Soyad 
                 Cross-Linker 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Solids (%) 
                 50.0 
                 45.0 
               
               
                   
                 Viscosity (cP) 
                 1500 
                 250 
               
               
                   
                 pH 
                 4.2 
                 5.5 
               
               
                   
                   
               
             
          
         
       
     
         [0053]    The method for using these products together is as follows: Mix the two components no more than 4 hours prior to its intended use; charge the Soyad (D-40999) to a mixing vessel; add the cross-linker (D-40767) such that the ratio is 20 parts cross-linker to 100 parts of Soyad on a solids basis; stir material 5-10 minutes such that resultant mixture is homogeneous. The solids, viscosity and pH of the resultant blend will be 49.1%, ˜1000 cP and ˜4.5, respectively. 
         [0054]    Continuing with  FIG. 1 , it can be seen that once the  sorghum  stalk portions have been combined with binder, the coated  sorghum  stalk material is placed into one or more layers (boxes  12   a - c ) 
         [0055]      FIG. 2  shows a fin/frame assembly  13  for orienting and layering binder coated  sorghum  stalk material  14 . It can be seen that the fin/frame assembly  13  includes a plurality of spaced apart parallel fins  15   a - c  that are secured to a wooden frame  16  to establish the fin/frame assembly  13 . As shown, the binder coated  sorghum  stalk material  14  is passed through the fins  15   a - c  to produce layer  20   a  on top of previously deposited layer  20   b . As shown, the fins  15   a - c  are aligned parallel to a desired layer axis  24   a  for the layer  20   a . Once a layer  20   a,b  is complete, the fin/frame assembly  13  can be lifted and reoriented, e.g. rotated, to prepare for loading stalk material  14  in a subsequent layer. For the fin/frame assembly  13 , the height of the fins  15   a - c  can be used to gauge and regulate the layer height. The number and spacing of the fins  15   a - c  can be varied to increase or decrease the variation in alignment of the stalk material  14  in the layer  20   a,b . The frame  16  can be sized to produce the desired OSSB sheet size, for example, to produce a 4′×8′ sheet, a suitable frame  16  of about 5′×9′ may be employed. Typically, a fin spacing in the range of about 2-3 inches may be used. A typical pre-compressing layer depth in the range of about 4 to 5 inches may be used. 
         [0056]      FIG. 3  shows a stack  26  having three layers  20   a - c , with each layer  20   a - c  oriented orthogonal to adjacent layers  20   a - c . Specifically, as shown, top layer  20   a  has a layer axis  24   a , layer  20   b  has a layer axis  24   b  and bottom layer  20   c  has a layer axis  24   c . For  FIG. 2 , it can be seen that layer axis  24   a  is substantially parallel to layer axis  24   c  and layer axis  24   b  is substantially orthogonal to both layer axis  24   a  and layer axis  24   c . Although three layers  20   a - c  are shown, it is to be appreciated that more than three and as few as one layer  20   a - c  may be used. Typically, to produce a board having superior strength along one of the board axes, an odd number of layers  20   a - c  are used and the exterior layers (e.g. layers  20   a  and  20   c ) are aligned in parallel. Typically, as shown in  FIG. 2 , in each layer  20   a , the stalk material  14  is oriented along a layer axis  24   a  such that at least 90% of said  sorghum  stalk material  14  is aligned within +/−45 degrees of the layer axis  24   a . In some implementations, the stalk material  14  may be combined with binder after orienting and/or layering. As an alternative to the fin/frame assembly  13  shown in  FIG. 2 , mechanized equipment (not shown) similar to equipment used in traditional wood OSSB manufacturing can be used to orient and layer the coated  sorghum  stalk material  14 . 
         [0057]      FIG. 1  shows that once the coated  sorghum  stalk material has been layered, the stack is pressed (box  30 ).  FIG. 4  shows a stack  26  having layers  20   a - c  positioned between release coated press platens  32   a,b . The stack  26  may be layered directly on a press platen  32   a  or the stack  26  may be layered and then placed onto the platen  32   a . Once positioned, the stack  26  of layers  20   a - c  may be thermocompressed in a press (not shown) between heated flat platens  32   a,b . One or more thermocompressions may be employed. Press temperature, pressure and duration may depend on board thickness and desired board density. Typically, thickness and density are specified, and the layer/stack input thickness and press pressure are varied, to obtain the desired final board thickness and density. Typically, a precompressed stack thickness of about 4-5 inches will compress to about ½ inch. Typical range of press temperatures include 125 deg F. to about 400 deg F., typical pressures include 100-300 psi and typical compressions include 2-5 minutes closing time and 3-10 minutes duration. In one implementation, a press temperature of about 150 deg F., press temperature of about 200 psi and a duration of about 5 minutes may be used.  FIG. 5  shows a plot of mat pressure (psi) and board thickness (in.) versus time for a thickness controlled press regimen to produce a board having a final desired thickness of about 0.55 inches. Shown plotted are the mat thickness 38 and mat pressure 40. Final board densities range from about 41 to 44 lbs/ft 3 . 
         [0058]    As shown in  FIG. 1 , after pressing (box  30 ), the board may be trimmed to size (box  36 ).  FIG. 6  shows a board  42  after pressing having an exterior layer axis  44  (i.e. the top and bottom layer having stalk material aligned along axis  40 ).  FIG. 7  shows the board  42  after trimming. 
       Example 
       [0059]    Single layer and three layer OSSB boards containing  sorghum  stalk material were prepared using stalks from energy  Sorghum  plants: 96% by weight, MIDI; 4% by weight and a final Density: 43.2 lb/ft 3 . Processing parameters for the three layers composites were:
       Hot-pressing temperature: 350 F   Duration: 6 min   Closing time: 4 min   Moisture content: 6%
 
Processing parameters for the one layer composites were:
   Hot-pressing temperature: 350 F   Duration: 5 min   Closing time: 3 min   Moisture content: 8%       
 
         [0068]      FIGS. 8-13  show density modified properties of the one layer and three layer boards. MOR, MOE and IP properties are influenced by density, and the data shown has been normalized by density. 
         [0069]    While the particular embodiment(s) are described and illustrated in this patent application in the detail required to satisfy 35 U.S.C. 112, it is to be understood by those skilled in the art that the above-described embodiment(s) are merely examples of the subject matter which is broadly contemplated by the present application. Reference to an element in the following Claims in the singular, is not intended to mean, nor shall it mean in interpreting such Claim element “one and only one” unless explicitly so stated, but rather “one or more”. All structural and functional equivalents to any of the elements of the above-described embodiments) that are known, or later come to be known to those of ordinary skill in the art, are expressly incorporated herein by reference arid are intended to be encompassed by the present Claims. It is not intended or necessary for a device or method discussed in the Specification as an embodiment, to address or solve each and every problem discussed in this Application, for it to be encompassed by the present Claims. No element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the Claims. No claim element in the appended Claims is to be construed under the provisions of 35 U.S.C. 112, sixth, paragraph, unless the element is expressly recited using the phrase “means for” or, in the case of a method claim, the element is recited as a “step” instead of an “act”.