Note: Descriptions are shown in the official language in which they were submitted.
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TITLE OF THE INVENTION
ORIENTED STRAND BOARDS COMPRISING
SPECIALTY PAPER
FIELD OF THE INVENTION
The present invention relates to oriented strand
boards (OSB). More specifically, the present invention is concerned
with an OSB that includes specialty paper strands.
BACKGROUND OF THE INVENTION
Oriented Strand Boards or OSBs are well known in
the art. A unique feature of OSB that long wood strands are oriented,
not randomly placed. In North America, the OSB has virtually replaced
other panels in new residential construction. All model-building codes
in the U.S. and Canada recognize OSB panels for the same uses as
plywood on a thickness-by-thickness basis.
Oriented Strand Board (OSB) is an engineered, mat-
formed panel product made of strands, flakes or wafers sliced from
small diameter, round wood logs and bonded with an exterior-type
binder under heat and pressure.
Figure 1 shows a prior art OSB structure as it is
produced across the industry. The OSB consists of layered mats
(Layers 1, 2, 3, and 4). Exterior or face layers 1 and 4 are composed
of strands aligned in the long panel direction; these strands represent
about 55% of the mat. Inner-layers 2 and 3 consist of cross- or
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randomly-aligned strands; these strands represent about 45% of the
mat. These large mats are then subjected to intense heat and pressure
to become a "master" panel and are cut to size. The thickness of each
layer (t1, t2, t3, t4) depends on specific board thickness.
It should be noted that wafers in core layers could
also be randomly distributed. The mechanical and chemical
resistances depend on wood species.
Strand dimensions are predetermined and have a
uniform thickness. The majority of structural board mills use a
combination of strands up to 6" (150mm) long and 2" (25mm) wide.
OSB's strength is mainly provided from the
uninterrupted wood fiber, interweaving of the long strands or wafers,
and degree of orientation of strands in the surface layers. Waterproof
and boil proof resin binders are combined with the strands to provide
internal strength, rigidity and moisture resistance.
OSB, as a performance-based structural use panel, is
recognized by all major U.S. model code agencies through the
adoption of DOC PS2-92 Wood-Based Structural Use Panels. Certified
to CSA 0325 and CSA 0437, OSB is accepted in the National Building
Code of Canada, certified to EN 300 and recognized for structural use
in Europe and certified to meet the JAS standard for structural panels
in Japan. Members of the Structural Board Association are specialists
in OSB and are committed to "Total Quality" manufacture of OSB and
waferboard for use in North America and overseas.
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There are many steps in the manufacturing process of
an OSB. The following is a brief description of these steps:
~ Log sorting: After harvest, whole aspen (or south
yellow pine) logs are hauled to the mill's wood yard, and then sorted.
~ Jackladder: Logs are soaked to remove ice and
prepare wood for stranding then sent up the jackladder.
~ Debarking: Logs are run through the debarker to
remove bark. Bark is later used as fuel in the mill's energy supply.
~ Stranding: The strands are cut from whole logs
into precise dimensions of up to six inches long.
~ Wet bins: Strands are deposited into wet bins.
~ Drying: Strands are then dry until the appropriate
moisture content is reached.
~ Dry bins: Strands are deposited into dry bins.
~ Blending: Where strands are blended with resin
binders (such as phenol-formaldehyde (PF) resin or poly-isocyanate
resin often called PMDI) and a small amount of wax, which improves
the efficiency of the resin binder and enhances the panel's resistance
to moisture and water absorption.
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~ Forming line: Strands go through the forming line
where cross-directional layers are formed.
~ Pressing: Where layers of strand are pressed under
intense heat and pressure to form a rigid, dense structural panel of
oriented strands or OSB. In the case of a multi-opening press, there
are three steps. The first step in press cycle consists of closing the
press platens to the desired target board thickness; the final position of
the platens (nominal board thickness) must not be reached before the
core temperature is at a minimum temperature which is about 70°C-
80°C. This is to insure wood plasticity necessary for compression. The
first step represents about 26% of total press cycle for a 7/16" board.
The second step consists in maintaining the mat of wafers between the
two platens for a given period of time until the resin is essentially set.
The temperature of the platens is normally greater than the minimum
temperature needed to activate and cure the resin (around 200°C). The
second step represents about 50% of the total press cycle. The third
and last step consists in releasing the pressure inside the mat (about
24% of total press cycle). This is done by slightly opening the platens
for a short period of time and then by completely opening the press and
ejecting the essentially completed board.
~ Finishing line: Panels are cooled, cut to size, grade
stamped, stacked in bundles and edge coated. All graded panels bear
a mandatory certification agency stamp, plus the SBA logo if
applicable.
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~ Shipping: Finally, the panels are ready to be loaded
and shipped to destinations around the world. Panels can be ordered
smooth sanded for special uses or with tongue and groove edges.
5 It is understood that the resulting is made of untreated
wood strands (raw material e.g. wood strand cut from logs). Moreover,
depending of the geographical location of the mill, boards are made
from unique wood species, which are available close to the mill such as
aspen for the northern mills (mostly in Canada) and south yellow pine
for the southern mills (US south) to give but two examples.
Board properties such as density, mechanical
resistance (MOE, MOR etc.), resistance to chemicals, swelling, internal
bond (IB), as well as other properties are dependent on wood species.
In the manufacturing process of an OSB, there are
limited and costly ways to improve board properties, such as adding
more resin (glue); increasing press cycle time; increasing temperature
of the platen press, among others.
There thus remains a need for an improved OSB.
OBJECTS OF THE INVENTION
An object of the present invention is to provide an
improved oriented strand board.
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SUMMARY OF THE INVENTION
More specifically in accordance with the present
invention, there is provided an oriented strand board (OSB) comprising
specialty paper, wherein the specialty paper confers its particular
physical and/or chemical properties to the OSB.
In accordance with another aspect of the present
invention, there is provided an oriented strand board (OSB) comprising
wood and specialty paper, wherein the specialty paper confers its
particular physical, mechanical and/or chemical properties to the OSB.
In accordance with a further aspect of the present
invention, there is provided a method of selectively improving,
enhancing and/or modulating one or more particular physical,
mechanical and/or chemical properties of an oriented strand board
(OSB), the method comprising:
adding one or more types of specialty paper
demonstrating one or more particular physical, mechanical and/or
chemical properties to the OSB during manufacture thereof so as to
confer to the OSB this one or more physical, mechanical and/or
chemical properties.
In accordance with yet another aspect of the present
invention, there is provided a method of selectively improving,
enhancing and/or modulating one or more particular physical,
mechanical and/or chemical properties of an oriented strand board
(OSB), the method comprising:
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identifying one or more specialty papers
demonstrating this one or more particular physical, mechanical and/or
chemical properties; and
adding this identified one or more specialty papers to
the OSB during manufacture thereof.
In accordance with yet a further aspect of the present
invention, there is provided a method of selectively improving,
enhancing and/or modulating one or more particular physical,
mechanical and/or chemical properties of an oriented strand board
(OSB), the method comprising:
manufacturing a specialty paper demonstrating one or
more desired particular physical, mechanical and/or chemical
properties; and
adding this manufactured one or more specialty
papers to the OSB during manufacture thereof.
The term "specialty paper" should be construed herein
to include without limitation: paper that is often suitable for special
purposes, because it possesses unique characteristics and properties,
and is not considered to be one of the standards by the paper industry;
coated and uncoated paper designed and produced to meet the unique
packaging, printing and labeling needs of customers with diverse and
specialized paper needs (non-limiting examples include household
papers, sanitary papers, base paper of wallpapers, wall paper,
decorated sheathing paper, decorating paper, decorative paper,
hanging paper, labels, sack papers, wrapping papers, envelopes,
packaging, flexible packaging and industrial papers); paper that is not
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commonly used in the Printing and Publishing shops; an asbestos-
containing product that is made of paper intended for use as filters for
beverages or other fluids or as paper fill for cooling towers (cooling
tower fill consists of asbestos paper that is used as a cooling agent for
liquids from industrial processes and air conditioning systems); paper
that correspondence to specific criteria such as for example, resistance
to grease, or that has a dull finish (i.e. low in gloss) or a glossy finish or
any other type. The term "specialty paper" as well the production
thereof and specific modification thereof - in order to modulate the
particular physical, mechanical and/or chemical properties thereof is
well understood by the ordinarily skilled artisan and should be
construed as such within the context of the present invention.
In accordance with an embodiment of the invention,
anon-limiting advantage of the present invention is that it provides an
OSB including specialty paper so as for the specialty paper to confer its
properties to the OSB.
Other objects, advantages and features of the present
invention will become more apparent upon reading of the following non
restrictive description of embodiments thereof, given by way of
example only with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the appended drawings where like elements are
referenced by like reference numerals and in which:
Figure 1 is a schematic exploded view of a prior art
OSB structure; and
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Figure 2 is a schematic exploded view of an OSB
structure in accordance with an embodiment of the present invention.
DESCRIPTION OF THE EMBODIMENT
With reference to the appended drawings an
embodiment of the invention will be herein described so as to exemplify
the invention and not limit its scope.
There are countless different paper types with specific
physical or mechanical and chemical properties that are available to
the public.
With reference to Figure 2, the present invention uses
strands made of these specialty papers to manufacture an OSB having
improved mechanical and/or chemical properties.
Layers 10 and 20 are made of paper and wood
strands respectively and together form a superior face. Layers 30 and
40 form the superior and inferior core of the OSB and are both made of
wood strands. Layers 50 and 60 are made of wood and paper strands,
respectively, and form the inferior face of the OSB.
In the embodiment illustrated herein, the paper
strands are in the exterior faces of the OSB, yet it may be
contemplated that specialty paper strands are layers 10, 20, 30, 40, 50
and 60 or any combination thereof.
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The number of layers shown in this particular example
is six however, yet the number of layers could be varied. When varying
the number of layers any layer or layers may be made of this these
specialty paper strands.
5
The thickness of each layer varies accordingly with
the specific board property that is sought to be improved. However, the
final thickness of the board may remain the same.
10 In an embodiment, a board is manufactured from
special paper strands only.
In another embodiment, the OSB is made of mixed
strands having specialty paper impregnated therein. Other materials,
such as resins or plastic for example, may also be added to the
mixture.
The present invention seeks to use any type of
specialty paper in order to confer the physical, mechanical and/or
chemical properties of that specialty paper to the OSB that is to be
manufactured. If a given specialty paper having a desired physical
property is not available, then it is contemplated within the scope of the
present invention to first manufacture a type of paper having a
particular physical, mechanical and/or chemical property and adding
this specialty paper to the OSB that is to be manufactured.
The following are non-limiting examples of three types
of specialty paper, including their specifications that are used in the
context of the present invention in order to confer their properties to the
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board manufactured in accordance with the invention:
EXAMPLE 1
COATED EXTENSIBLE KRAFT (Grade 486)
TARGET _MINIMUM MAXIMUM
BASIS WEIGHT 50.000 47.499 52.499
LB/3000P12
FORMATION 1.000
MULLEN PSI 50.000 45.000
POROSITY 35.000
SEC/100ML
MOISTURE % 4.500 4.000
TENSILE C.D. 17.000 11.200
LBF/INCH
TENSILE TOTAL 48.000 32.200
LBF/INCH
TEAR M.D. (GF/16 118.000 110.000
PLIES
TOTAL TEAR (GF/16 245.000 235.000
PLIES
STRETCH M.D. % 6.000 5.000
INK TEST SEC. 325.000 186.000 800.000
All tests are done at 50% relative humidity and 23 degrees Celsius.
EXAMPLE 2
FIRE PROOF ALUMINIUM LAM. PAPER (Grade 5025)
TARGET M MAXIMUM
INI
MUM
BASIS WEIGHT 29.000 _ 30.499
_
~ 27.599
LB/3000P12
FORMATION 1.000 5.000
CALIPER MILS 2.700 2.100 3.000
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MULLEN PSI 2_1.000
POROSITY (SEC/100 25.000 20.000
ML
MOISTURE % 3.500 3.000
TENSILE C.D. 11.000
LBF/INCH
TENSILE M.D. 22.000
LBF/INCH
TEAR M.D. (GF/16 47.000
PLIES
TEAR C.D. (GF/16 58.000
PLIES
COBB 2 MINUTES .180
G/100CM2
SMOOTHNESS FELT 260.000 300.000
SHEFFIELD
All tests are done at 50% relative humidity and 23 degrees Celsius.
EXAMPLE 3
MULTIWALL BAG (RWS) (Grade 410)
TARGET MINIMUM MAXIMUM
BASIS WEIGHT 50.000 47.499 52.499
LB/3000P12
FORMATION 1.000 5.000
MULLEN PSI 45.000 35.000
WET MULLEN PSI 15.000 12.000
POROSITY (SEC/100 20.000
ML
MOISTURE % 7.000 4.500
TENSILE C.D. 23.000 14.700
(LBF/INCH)
TENSILE M.D. 40.000 25.900
LBF/INCH
TEAR M.D. (GF/16 110.000 95.000
PLIES
TEAR C.D. (GF/16 125.000 106.000
PLIES
INK TEST SEC. 335.000 186.000 800.000
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All tests are done at 50% relative humidity and 23 degrees Celsius.
Of course, all other specialty papers may be used in
the context of the present invention.
During the manufacturing process the following is
considered:
The paper is selected in accordance with a particular
board property or particular properties that are sought to be improved
or modified. In one non-limiting example, using very strong paper
strands for the faces produces faces having a greater density as
compared to wood strands so that board-bending property (MOE) is
significantly improved.
It should be noted that there is no limit regarding the
length, width and thickness of the paper strands. Hence, paper strands
of various configurations, sizes and materials are used within the
context of the present invention.
Furthermore, there is no limit regarding the number of
paper strand layers. The number of layers is determined by what
degree we want to improve board properties.
By using paper strands, the chemical and mechanical
resistance is improved. Moreover, the look of the new board is much
better.
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The percentage range of the specialty paper with
respect to the OSB panel will depend on the effect (i.e. improved or
enhanced properties) that is sought.
In one non-limiting example, the ratio of wood that can
be used for the superior and inferior faces as well as the core of the
OSB can be about 50%.
In another example, if the user seeks to treat the
external surfaces of a new OSB so as to improve or enhance certain
selected properties than the percentage of paper used can be greater
than 0% to about 50% of that external surface. In still another example
the external face may be made completely from specialty paper
strands.
In an example, if the manufacturer desires to improve
the impact resistance of the OSB, extendible paper is added to the
core instead of wood strands. This extensible paper can make up
between more that 0% to about 50% of the core.
Hence, in accordance with the present invention the
specialty paper strands may make up anywhere between more than
0% to 100% of the total material of the OSB panel.
It is to be understood that the invention is not limited
in its application to the details of construction and parts illustrated in the
accompanying drawings and described hereinabove. The invention is
capable of other embodiments and of being practised in various ways.
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It is also to be understood that the phraseology or terminology used
herein is for the purpose of description and not limitation. Hence,
although the present invention has been described hereinabove by way
of embodiments thereof, it can be modified, without departing from the
5 spirit, scope and nature of the subject invention as defined in the
appended claims.
