Method of manufacturing wood-like plywood substitute

Details Method of manufacturing wood-like plywood substitute Method of manufacturing wood-like plywood substitute

2011-07-12

2011-07-12

Maki, Steven D (Department: 1747)

Adhesive bonding and miscellaneous chemical manufacture

Methods

Surface bonding and/or assembly therefor

C019S163000, C156S148000, C156S199000, C156S204000, C442S402000, C442S407000

Reexamination Certificate

active

07976655

ABSTRACT:
Discarded or recycled carpets or other textiles can be converted into wood-like materials, in sheets comparable to plywood. The carpets or textiles are shredded, combed, and layered across a conveyor to form a low-density mat, which is compressed and needle-punched to create a cohesive but flexible mat. An adhesive is applied to at least one and preferably two or more mats, by an applicator that spreads a liquid prepolymer onto one or more surfaces of the mat(s). The mat(s) travel through a press while the adhesive cures and hardens, and the use of foaming adhesives can ensure uniform permeation through dense fiber mats. The hardened sheets can be sawed, nailed, and otherwise handled like wood, and are strong, durable, and highly resistant to damage by water or insects.

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