The invention relates to a method and devices for producing products (65) by using cellulose-containing particles, with which the following steps are carried out: a) irradiating the particles with electrons in the energy range >1 MeV: b) mixing the irradiated particles with electron-beam-reactive powder of a synthetic polymer, in particular a thermoplastic, having powder particle sizes <2000 micrometres and/or with a liquid electron-beam-reactive synthetic or bio-based polymer; c) forming the mixture created in a way corresponding to the form of the product to be produced, in particular forming it into a nonwoven (56): d) heating the formed mixture to 100-180° C.; e) pressing the formed mixture without heating; and f) irradiating the pressed mixture with electrons in the energy range of 1 MeV to 10 Me V and also with appropriately chosen dosages and dosing rates.

A method of producing a moulded article comprising a thermoset polymer and particles of porous natural materials, such as wood materials, and uses thereof. The composite material has a continuous matrix of a hardened thermoset polymer and, distributed within the matrix, and the particles are at least partially encased by the thermoset polymer. The method comprises the steps of providing a mould with two opposite pressing surfaces, said pressing surfaces defining a space between them; feeding particles of porous natural materials into the space between the pressing surfaces; advancing the surfaces towards each other to compress the particles in said space; feeding unhardened thermoset resin in liquid form into the mould so as to fill at least said space between pressing surfaces while keeping the particles compressed between the pressing surfaces; and curing the thermoset resin in the mould to provide a moulded composite article.

A method of producing a moulded article comprising a thermoset polymer and particles of porous natural materials, such as wood materials, and uses thereof. The composite material has a continuous matrix of a hardened thermoset polymer and, distributed within the matrix, and the particles are at least partially encased by the thermoset polymer. The method comprises the steps of providing a mould with two opposite pressing surfaces, said pressing surfaces defining a space between them; feeding particles of porous natural materials into the space between the pressing surfaces; advancing the surfaces towards each other to compress the particles in said space; feeding unhardened thermoset resin in liquid form into the mould so as to fill at least said space between pressing surfaces while keeping the particles compressed between the pressing surfaces; and curing the thermoset resin in the mould to provide a moulded composite article.

The present invention relates to a process for lignin dissolution in which partial methylolation of lignin is carried out during the step of preparing a solution of lignin in an aqueous medium comprising alkali and phenol. The lignin prepared according to the process of the present invention can be used to manufacture lignin-based phenolic resins, which are particularly useful in the manufacture of laminates.

A method for producing a board according to the present invention includes the steps of: (A) dispersing a polycarboxylic acid, a saccharide, and ammonium sulfate in a collection of small wood pieces; and (B) subjecting the collection of small wood pieces containing the dispersed polycarboxylic acid, saccharide, and ammonium sulfate to hot press molding to form a board comprising the small wood pieces bonded together.

The present disclosure is directed to molded door skins and methods of making. Methods include providing an at least partially consolidated flat wood composite blank. Methods further include positioning a stretchable film on an outer surface of the blank, and pressing the blank and the stretchable film together in a heated press to form the molded door skin. The molded door skin has a first surface and a second surface recessed relative to the first surface by a predetermined distance. A third planar portion extends between first and second planar portions at an angle in a range of 100 degrees and 120 degrees. Cracks or voids formed in the outer surface of the blank during the pressing are filled with the stretchable film such that an outer surface of the molded door skin is substantially or entirely crack and void free.

The present invention provides a chlorinated poly(propylene carbonate)/biomass composite material, comprising 3 wt % to 57 wt % of a chlorinated poly(propylene carbonate); 40 wt % to 94 wt % of a biomaterial; 2 wt % to 20 wt % of a rosin or a rosin derivative; 0 wt % to 1 wt % of an antioxidant; and 0 wt % to 5 wt % of a filler, wherein a sum of amounts of all components is 100 wt %. The chlorinated poly(propylene carbonate) functions as a binder, and plays an important role in the moisture resistance of the composite material. The rosin or the rosin derivative functions as a viscosifier and a lubricant, and can also improve the moisture resistance and mechanical property of the composite material. Under the synergistic effect of the above components, the composite material obtained in the present invention is excellent in both mechanical property and moisture resistance. Further, because the starting materials comprise a larger amount of biomass materials, the cost thereof is low, and because the starting materials contain no formaldehyde, benzene and the like, the material is environment friendly.

Engineered wood products and binder compositions are provided. In preferred embodiments, the engineered wood products include wax. Methods are also provided for formulating binders for wood comprising unmodified soy flour and synthetic adhesives. The soy-based formulations are prepared by mixing unmodified soy flour with the synthetic adhesive prior to application to the wood or by adding them sequentially to the wood. The present invention provides adequate bonding at reduced cost.

Engineered wood products and binder compositions are provided. In preferred embodiments, the engineered wood products include wax. Methods are also provided for formulating binders for wood comprising unmodified soy flour and synthetic adhesives. The soy-based formulations are prepared by mixing unmodified soy flour with the synthetic adhesive prior to application to the wood or by adding them sequentially to the wood. The present invention provides adequate bonding at reduced cost.

A composite wall panel having a front surface, a rear surface, and side surfaces extending therebetween is provided. The panel includes a cured composition of pieces of cellulose and/or chaff and at least one binder. A wall assembly is also provided. The assembly includes: a frame including a plurality of linearly arranged elongated studs having a top end, a bottom end, and a first longitudinal side and a second longitudinal side extending between the respective ends; a plurality of interconnected wall panels mounted to the first side of the elongated studs of the frame to form a first wall portion; a plurality of interconnected panels mounted to the second side of the elongated studs to form a second wall portion; and an insulating layer inserted within a cavity between the first wall portion and the second wall portion.