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 by 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, 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 article according to claim 1, wherein the wood chips are formed by platy particles having a planar surface and are least partially overlapping in a plane parallel to an outer surface of the article.

3. The article according to claim 1, wherein the wood chips form a 3-dimensional structure of interlocking chips at least in a zone adjacent to an outer surface of the article.

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

5. (canceled)

6. (canceled)

7. The article according to claim 1, wherein the thermoset polymer comprises a polyester resin, an epoxy resin, a urea formaldehyde resin, melamine formaldehyde resin, or melamine ureaformaldehyde resin.

8. (canceled)

9. (canceled)

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

11-14. (canceled)

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

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

17. The article according to claim 1, wherein the article has a density which is 10 to 40%, smaller than a density of the hardened thermoset polymer without the wood chips.

18. The 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 sieved size between 0.5-3 mm.

19. The article according to claim 1, further comprising a gelcoat coating formed by a isophthalic/neopenthylglycol polyester resin.

20. A method of producing an article comprising: blending wood chips with a liquid formed by unhardened thermoset resin at a weight ratio of 1:100 to 60:100 to obtain a uniform mixture; transferring the mixture into a compression mould having a receiving surface corresponding to an outer surface of the compressed article; and moulding the mixture in said mould under compression to form a compressed article having at least one surface formed against the receiving surface.

21. The method according to claim 20, further comprising: blending wood chips with a liquid formed by unhardened thermoset resin at a weight ratio of 10:100 to 40:100 to obtain a uniform mixture; transferring the mixture into a compression mould; and moulding the mixture in said mould at a temperature of less than the boiling point of water and under conditions which allow for the chips to form a 3-dimensional structure of interlocking chips within the thermoset resin during the compression.

22. The method according to claim 20, wherein the wood chips to be blended with the unhardened thermoset resin are capable of becoming impregnated with the unhardened thermoset resin.

23. The method according to claim 20, wherein the wood chips organize during moulding into an interlocking, 3-dimensional structure on at least said outer surface.

24. The method according to claim 20, wherein the mixture is hardened in the mould by catalyst activation at room temperature.

25. (canceled)

26. (canceled)

27. The method according to claim 20, wherein the wood chips are thermally treated before the blending.

28. (canceled)

29. The method according to claim 28, wherein the article is coated with a layer of a gelcoat formed by a isophthalic/neopenthylglycol polyester resin.

30. (canceled)

31. (canceled)

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

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

Description

EXAMPLE 1

[0069] 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.

[0070] 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

[0071] 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

Patent Literature

[0072] JP03055974B2

[0073] JP2014008617A

[0074] JP2002036213A

[0075] EP2777238

[0076] U.S. 2013000248 A1

[0077] U.S. 2003046772 A1