Compressed articles and methods of manufacturing the same

Abstract

A compressed article formed by a composite material comprising a thermoset polymer and a wood material, a method of producing the same and the use of the novel articles. The composite material has a continuous matrix of a hardened thermoset polymer and, distributed within the matrix, wood chips which are at least partially encased by the thermoset polymer, said article having a water absorbency of less than 1% by weight upon immersion into water over a time period of at least 168 h at room temperature. The articles can be used in structures that are frequently contacted with water.

Claims

1. A compressed article formed from a composite material comprising a continuous matrix of a hardened thermoset polymer and, distributed within the matrix, wood chips which are at least partially encased by the thermoset polymer, and a gelcoat coating comprising a isophthalic and neopenthylglycol polyester resin, wherein the wood chips are platy particles having a planar surface and are at least partially aligned with the longest dimension in a plane parallel to an outer surface of the article, wherein the article has a planar surface, and said article having a water absorbency of less than 1% by weight upon immersion into water over a time period of at least 168 h at room temperature.

2. The compressed article of claim 1, wherein the thermoset polymer comprises a polyester resin, an epoxy resin, melamine formaldehyde resin, or melamine urea formaldehyde resin.

3. The compressed article according to claim 1, wherein the wood chips have a sieved size of 1 to 7.5 mm.

4. The compressed article according to claim 1, wherein the compressed article comprises 1 to 60 parts by weight of the wood chips per 100 parts by weight of the hardened thermoset polymer.

5. The compressed article according to claim 1, wherein the wood chips are at least partially impregnated with the thermoset polymer.

6. The compressed article according to claim 1, wherein the compressed article has a density which is 2 to 20% smaller than the density of the hardened thermoset polymer without the wood chips.

7. The compressed article according to claim 1, further comprising having a water absorbency of less than 0.5% by weight upon immersion into water over a time period of at least 168 h at room temperature when using wood chips having a sieved size between 0.5-3 mm.

8. The compressed article according to claim 1, wherein the wood chips have a sieved size of 0.5 to 5 mm.

9. The compressed article according to claim 1, wherein the compressed article comprises 10 to 40 parts by weight of the wood chips per 100 parts by weight of the hardened thermoset polymer.

10. The compressed article of claim 1, wherein the compressed article is a furniture piece, plumbing fixture, boat hull, sink, tile, bathtub, or urinal.

Description

EXAMPLE 1

(1) 30 parts by weight of the wood chips (sieved size 1-3 mm) and 70 parts by weight of an unhardened unsaturated polyester resin activated with a peroxide hardener were mixed to form a uniform mixture. The polyester resin and the hardener were mixed together prior adding wood chips to the resin solution. The mixture was thoroughly blended with a mixer to obtain an even distribution of the components. The mixture was then transferred to a compression three dimensional mould. The mixture was then compressed at a pressure of at least 500 kN and at a temperature of 40° C. whereby the resin cured and a compressed article was formed having a smooth surface. The density of the product was ˜950 kg/m.sup.3.

(2) The compression moulded article was weighted and immersed into a water bath at a temperature of 25° C. After 168 hours, the article was removed from the water bath, the surface of the specimen was dried and the specimen then weighted. An increase of weight of less than 0.2% was found.

INDUSTRIAL APPLICABILITY

(3) The present articles have a broad range of uses. In particular, it can be used in structures which are subject to continuous or occasional contact with water. Thus, the articles can be employed in the production of furniture for indoor as well as for outdoor use. It can be used in fixtures for kitchens and bathrooms. Examples include sinks, tiles, bathtubs, urinals and other similar plumbing fixtures. The present articles can also be used in marine structures, on boats and similar vessels, as part of hull or deck.

CITATION LIST

(4) Patent Literature

(5) JP03055974B2

(6) JP2014008617A

(7) JP2002036213A

(8) EP2777238

(9) U.S. 2013000248 A1

(10) U.S. 2003046772 A1