The invention relates to an insulated panel, in particular a wall panel or roof panel, including a foamed core layer and a cover layer affixed to the foamed core layer. The invention also relates to an insulating covering, in particular a wall covering or floor covering, including a plurality said insulated panels.

An engineered wood based siding, cladding or panel with a pre-consolidated fines layer (PCF) applied to the top of the main strand matrix layers to minimize telegraphing and provide an improved surface appearance. The PCF is consolidated prior to application to the surface of the strand matrix or mat, and takes the place of a loose fines layer. The PCF prevents the loss of fines into the strand matrix, effectively keeping the fines at the surface so they can effectively and efficiently function to prevent or eliminate strand telegraphing, and provide a smooth finished surface for the product.

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.

The present invention relates to a process for the batchwise or continuous, preferably continuous production of multilayer lignocellulose materials with a core and with at least one upper and one lower outer layer, comprising the following steps: a) mixing of the components of the individual layers separately from one another, b) layer-by-layer scattering of the mixtures (for the core layer and for the outer layers) to give a mat, c) precompaction after the scattering of the individual layers, d) application of a high-frequency electrical field before, during and/or after the precompaction, and then e) hot pressing,
where, in step a),
for the core, the lignocellulose particles A) [component A)] are mixed with B) from 0 to 25% by weight of expanded plastics particles with bulk density in the range from 10 to 150 kg/m.sup.3 [component B)], C) from 1 to 15% by weight of one or more binders selected from the group consisting of aminoplastic resin and organic isocyanate having at least two isocyanate groups [component C)], D) from 0 to 3% by weight of ammonium salts [component D)], E) from 0 to 5% by weight of additives [component E)] and F) from 0.1 to 3% by weight of alkali metal salts or alkaline earth metal salts from the group of the sulfates, nitrates, halides and mixtures of these [component F)],
and for the outer layers, the lignocellulose particles G) [component G)] are mixed with H) from 1 to 15% by weight of one or more binders selected from the group consisting of aminoplastic resin and organic isocyanate having at least two isocyanate groups [component H)], I) from 0 to 2% by weight of ammonium salts [component I)], J) from 0 to 5% by weight of additives [component J)] and K) from 0 to 2% by weight of alkali metal salts or alkaline earth metal salts from the group of the sulfates, nitrates, halides and mixtures of these [component K)],
wherein, after step a), the mixture for the core comprises, based on the total dry weight of the mixture of components A) to F) from 3 to 15% by weight of water, the mixture(s) for the outer layers comprise(s), based on the total dry weight of the mixture(s) of components G) to K), from 5 to 20% by weight of water, and the following conditions are met: component F)≧1.1•component K) and [component F)+component D)]≧1.1•component K)+component I

The present invention relates to a process for the batchwise or continuous, preferably continuous production of single-layer lignocellulose-based boards or of multilayer lignocellulose-based boards with a core and with at least one upper and one lower outer layer,

comprising the following steps: a) mixing of the components of the individual layer(s), b) layer-by-layer scattering of the mixtures to give a mat, c) compaction after the scattering of the individual layer(s), d) application of a high-frequency electrical field, during and/or after the compaction and thermal hardening of the binder(s), e) then optionally hot pressing, and f) cooling the lignocellulose material,

where, in step a),

for the core or the single layer, the lignocellulose particles A) [component A)] are mixed with B) from 0 to 25% by weight of expanded plastics particles with bulk density in the range from 10 to 150 kg/m.sup.3 [componeent B)],, C) from 1 to 15% by weight of one or more binders selected from the group consisting of aminoplastic resin and organic isocyanate having at least two isocyanate groups [component C)], D) from 0 to 3% by weight of ammonium salts [component D)], E) from 0 to 5% by weight of additives [component E)] and F) from 0.1 to 3% by weight of alkali metal salts or alkaline earth metal salts from the group of the sulfates, nitrates, halides and mixtures of these [component F)],

and optionally for the outer layers, the lignocellulose particles G) [component G)] are mixed with H) from 1 to 15% by weight of one or more binders selected from the group consisting of aminoplastic resin and organic isocyanate having at least two isocyanate groups [component H)], I) from 0 to 2% by weight of ammonium salts [component I)], J) from 0 to 5% by weight of additives [component J)] and K) from 0.1 to 3% by weight of alkali metal salts or alkaline earth metal salts from the group of the sulfates, nitrates, halides and mixtures of these [component K)],

wherein at the juncture Z the temperature of the layer of the core or of the single layer is more than 90°C., and this temperature is reached in less than 40 s/mm d after the application of the high-frequency electrical field, where d is the thickness of the sheet of lignocellulose material at the juncture Z.

A method of producing a veneered element, including providing a substrate, applying a sub-layer on a surface of the substrate, applying a veneer layer on the sub-layer, and applying pressure to the veneer layer and/or the substrate, such that at least a portion of the sub-layer permeates through the veneer layer. Also, such a veneered element.

The invention relates to a method for foaming chipboard with tubes including a board body interspersed by tubes and having an upper and a lower face includes the steps of providing a corresponding chipboard with tubes, defining one or more machining regions on the upper and/or lower face of the chipboard with tubes, machining the machining regions.

In order to provide a method for foaming chipboard with tubes and a chipboard with tubes having foamed tubes that can be used in a simple, flexible, and cost-effective manner while also being highly robust, a foam-forming material is introduced at least in portions of at least one of the above-mentioned tubes in the machining region in order to locally reduce the difference in density between the tubes and the board body. The invention further relates to the use of a device for foaming tubes of a chipboard with tubes.

A building panel with a surface layer including a wood veneer, a wood fibre based core and a sub-layer between the surface layer and the core. The sub-layer includes wood fibres and a binder. The surface layer has surface portions including material from the sub-layer. The surface portions including material from the sub-layer extend into the wood veneer.

A method of manufacturing a foam molded product having a reinforcement layer including a short fiber provided on a surface layer. The method includes the following steps. In a fiber layer formation step, the short fiber is adhered to and deposited on a cavity surface of a mold to form a fiber layer. In a covering step, a silicone rubber sheet is arranged on the mold to cover the fiber layer. In a compression step, air is sucked between the silicone rubber sheet and the cavity surface to compress the fiber layer by the silicone rubber sheet and the cavity surface. In a molding preparation step, the silicone rubber sheet is removed from the fiber layer after compression, a foam material is suppled into a cavity of the mold, and the mold is clamped. In a molding step, the foam material in the cavity is foamed and cured.

Methods and systems that can produce light weight reinforced thermoplastic articles are described. In some embodiments, a method includes heating and pressing a core layer and then cooling and pressing the core layer to maintain the thickness of the core layer during cooling. Automotive articles, building articles and recreational vehicle articles that can be produced using the methods and systems are also described.