Improved wood strand panels suitable for construction are produced by first thermally modifying a plurality of wood strands that are thin in terms of thickness. Then, wood veneers are constructed from the thermally modified wood strands, at least some of which partially overlap one another. The wood veneers are on the order of 0.125 to 0.25 inches thick. Finally, the wood veneers, constructed from the thermally modified wood strands, are stacked on top of one another and connected using adhesive, pressure and temperature similar to plywood or LVL manufacture. The thermal modification and use of thin strands, followed by veneer formation, prior to manufacture of the composite results in a composite with uniform density, high-strength, resistance to decay, resistance to water sorption, and other benefits.

Improved wood strand panels suitable for construction are produced by first thermally modifying a plurality of wood strands that are thin in terms of thickness. Then, wood veneers are constructed from the thermally modified wood strands, at least some of which partially overlap one another. The wood veneers are on the order of 0.125 to 0.25 inches thick. Finally, the wood veneers, constructed from the thermally modified wood strands, are stacked on top of one another and connected using adhesive, pressure and temperature similar to plywood or LVL manufacture. The thermal modification and use of thin strands, followed by veneer formation, prior to manufacture of the composite results in a composite with uniform density, high-strength, resistance to decay, resistance to water sorption, and other benefits.

The invention relates to a process for producing a thermoformable and/or embossable particle/polymer composite using a substrate S based on shredded polymer-coated paper and a thermoplastic polymer P, therewith providing a new method of recycling/upcycling paper waste. Furthermore, a process for the manufacturing of a molded article obtained from the paper-based particle/polymer composite and its use as an element in buildings or in furniture are disclosed.

A process for the production of particle board, MDF board or HDF board includes the step of recycling particle board material, MDF and/or HDF board material in which recycled chips and/or recycled wood fibers are produced. The process includes the step in which the particle board material, the MDF and/or HDF board material is wetted, heated and pressurized, such that this material is kept under pressure and at an elevated temperature for a certain time. The process involves the step of supplying the recycled chips and/or the recycled wood fibers as base material in a production process of particle board, MDF board or HDF board.

A method of dissolving lignocellulosic biomass waste includes obtaining raw lignocellulosic biomass waste, reducing a size of the biomass waste to provide a biomass particle size of less than about 200 μm; using dimethyl sulfoxide (DMSO), sodium hydroxide (NaOH) and trifluoroacetic acid (TFA) solvents to dissolve the biomass particles and achieve a dissolved lignocellulose solution. The present method dissolves at least about 94% of the lignocellulose fraction in the waste biomass. In an embodiment, the biomass particle size can be about 180 μm.

The present disclosure provides an engineered wood precursor mixture. The mixture includes a wood substrate(s) and a binder reaction mixture present in a range of from 3 to 25 parts per one hundred (100) parts of the dry weight of the wood substrate. The binder composition includes an aqueous portion. The aqueous portion includes a carbohydrate-containing component, including glucose, fructose, sucrose, or mixture thereof, in a range of from 2 wt % to 85 wt % based on a dry weight of the binder reaction mixture. The aqueous portion further includes 1 wt % to 33 wt % of a base based on a dry weight of the binder reaction mixture, wherein a pH of the aqueous portion is greater than 10. The binder composition further includes a partially non-dissolved polypeptide-containing component, in a range of from 20 wt % to 85 wt % based on the dry weight of the binder reaction mixture.

The present disclosure provides an engineered wood precursor mixture. The mixture includes a wood substrate(s) and a binder reaction mixture present in a range of from 3 to 25 parts per one hundred (100) parts of the dry weight of the wood substrate. The binder composition includes an aqueous portion. The aqueous portion includes a carbohydrate-containing component, including glucose, fructose, sucrose, or mixture thereof, in a range of from 2 wt % to 85 wt % based on a dry weight of the binder reaction mixture. The aqueous portion further includes 1 wt % to 33 wt % of a base based on a dry weight of the binder reaction mixture, wherein a pH of the aqueous portion is greater than 10. The binder composition further includes a partially non-dissolved polypeptide-containing component, in a range of from 20 wt % to 85 wt % based on the dry weight of the binder reaction mixture.

A process for producing a lignocellulose-containing, plastic-coated and printable molding (26), in particular in sheet form, comprising the steps of: a) producing a layer (A, B′) containing lignocellulose-containing particles according to the shape of the molding to be produced (26); b) applying a layer (C) of particles containing electron beam-reactive thermoplastic onto the layer produced according to the preceding feature; c) heating the layers (A, C) produced according to the preceding features such that thermoplastic particles melt into the layer containing lignocellulose-containing particles (Cs); d) pressing the layers heated according to feature (1c); and e) irradiating the layers pressed according to feature (1d) with electrons in the energy range from 1 MeV to 10 MeV. The process is for example elucidated with reference to an MDF sheet one-sidedly provided with a polymer layer.

A method of manufacturing a separate and continuous layer being essentially uncured. The method includes applying a powder mix including fibres and a thermosetting binder on a carrier, forming a powder mix layer, wherein the powder mix is connected together such that the powder mix layer is obtained and wherein the powder mix layer is essentially uncured, and releasing the powder mix layer from the carrier. Also, a layer and a method for manufacturing a building panel.

Methods of forming a lightweight reinforced thermoplastic core layer and articles including the core layer are described. In some examples, the methods use a combination of thermoplastic material, reinforcing fibers and bicomponent fibers to enhance retention of lofting agents in the core layer. The processes permit the use of less material while still providing sufficient lofting capacity in the final formed core layer.