Stock material or miscellaneous articles – Composite – Of carbohydrate
Reexamination Certificate
2002-09-20
2004-02-03
Kiliman, Leszek (Department: 1773)
Stock material or miscellaneous articles
Composite
Of carbohydrate
C428S536000, C428S537100, C524S013000, C524S014000, C524S016000
Reexamination Certificate
active
06686056
ABSTRACT:
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND
This invention relates to the incorporation of a drying oil and a copper containing preservative system into wood products, which may include lumber and plywood, and into wood and agricultural based composite products. Wood based composite products can include products such as oriented strandboard, medium density fiberboard, fiberboard, hardboard, and particle board. The invention also relates to the method of manufacturing wood based composite products whereby a drying oil and a wood preservative composition are added to the wood furnish (defined as wood strands, chips, particles, flakes and fiber), plywood (whether in the form of separate plies or a bound sheet), or solid wood prior to or after drying. Where a wood furnish or separate wood plies are treated, the wood is then formed and pressed into a finished board or panel product.
The production of wood based composite panel products has increased dramatically in recent years. Oriented strandboard (OSB) production exceeded that of plywood in the Year 2000. In order to continue this new growth, additional uses for OSB need to be developed. Common applications for these products include roof sheathing, wall sheathing, flooring, structural insulated panels and engineered wood components such as I-joists. With the ever-expanding production capacity of wood based composites there is a critical need to find additional uses.
The use of medium density fiberboard and hardboard panel products likewise has increased dramatically over the last couple decades. However, these products are typically used in interior applications where attack from insects or decay fungi is limited and dimensional stability is not of great concern. The market for these types of materials is fairly well developed. To maintain market share and increase production it will be necessary to develop new products that can withstand exterior environments.
The expansion of wood fiber, particle and flake based composites into certain construction applications is hindered by limitations in the physical and mechanical properties of the manufactured panels, in particular excessive water absorption and propensity to swell, but also by their susceptibility to attack by biological agents such as decay fungi and termites.
Chemical preservatives and water repellent treatments are available for solid lumber and plywood. Such chemical treatments are applied to lumber, millwork, wood plies, and so forth using vacuum pressure processes to ensure uniform distribution of the active ingredients throughout the wood components. Treated woods find application in the construction of residential housing and commercial buildings.
Historically, attempts to incorporate chemical treatments into wood based composites using similar technology have failed for economic reasons or more commonly because of technical problems associated with irreversible and excessive swelling of the treated panels and severe loss of structural integrity.
The development of an economically viable preservative/water repellent treatment for solid wood, plywood, and wood based composites with minimal or no impact on board structural properties, would be desirable to the industry and consumers.
The development of such products would have a significant impact upon the forest resources of North America as well as the world. Solid wood or a formed panel product that has been treated to resist biological action and is inherently stable to resist water will significantly increase the service life of the final wood product. Hence replacement of damaged, decayed, or destroyed panels will be less frequent. Therefore, more solid wood and wood fiber can be channeled to new construction and not the replacement market. This will limit the stress on the forest resources of North America, which have been shrinking over the last two decades due to land being tied up in “natural” status, which cannot be harvested.
U.S. Ser. No. 09/550,027, filed Apr. 14, 2000, now U.S. Pat. No. 6,565,540, entitled: Dimensionally Stable Wood Composites And Methods For Making Them, discloses treated wood composites and their ingredients and manufacture. The latter application is incorporated by reference in its entirety.
PCT patent application WO 92/19429, published Nov. 12, 1992, in Example 2, describes a method of treating an article of prepared wood by immersing it for 20 minutes in a bath of 180° C. linseed oil containing a drier (siccative) of 0.07% lead, 0.003% manganese and 0.004% calcium and 0.3% copper naphthenates and 0.03 zinc naphthenates as an insecticide and fungicide.
U.S. Pat. Nos. 5,607,633, 5,719,301, and 6,277,310 describe bonding composite panels such as oriented strand board, particle board, plywood, MDF, hardboard, and similar panels, using a material such as linseed oil, which may be modified to provide bonding characteristics.
Fojutowski, A.; Lewandowski, O,
Zesz. Probl. Postepow Nauk Roln.
No. 209: 197-204 (1978), describes fungicides comprising fatty acids with copper compounds, applied by dipping hardboard heated to 120° C. into a bath of the fungicide, also maintained at 120° C.
Japanese Patent Application 08-183,010 JP, published in 1996, describes a modified wood claimed to have mildew-proofing and antiseptic properties and ant-proofing properties, made by treating wood with a processing liquid containing a composite multivalent metal (one example of which is copper) salt and linseed oil or another liquid hardening composition. The abstract states that the composite multivalent metal salt is strongly fixed within the material so as to let the composite multivalent metal salt give antibacterial properties, antiseptic properties, ant-proofing properties, water repellency and strength to wood.
U.S. Pat. No. 3,837,875 describes as a composition for cleaning, sealing, preserving, protecting and beautifying host materials such as wood a mixture of boiled linseed oil, turpentine, pine oil, a dryer and atomized metallic copper with the copper being present in a ratio of about 28 parts per million.
Feist, William C.; Mraz, Edward A., Forest Products Lab Madison Wis.,
Wood Finishing: Water Repellents and Water
-
Repellent Preservatives. Revision,
Report Number-FSRN-FPL-0124-Rev (NTIS 1978) discloses preservatives containing a substance that repels water (usually paraffin wax or related material), a resin or drying oil, and a solvent such as turpentine or mineral spirits. Addition of a preservative such as copper naphthenate to the water repellent is asserted to protect wood surfaces against decay and mildew organisms.
Soviet Union Patent No. SU 642166 describes a wood surface staining and preservation treatment, carried out by impregnating wood with an aqueous copper salt solution, followed by thermal treatment in boiling drying oil containing 8-hydroxyquinoline dye. The copper salt and the dye form a complex which is stated to stain and preserve the wood.
Schultze-Dewitz, G.,
Improvement of Beech Wood,
H
OLZFORSCHUNG UND
H
OLZVERWERTUNG
Vol. 46, No. 2, 1994 pp. 34-39, states that specimens of beech wood in air-dried, green, and water-stored conditions (about 15, 120 and 150-180% moisture content, respectively) were impregnated with nine different chemicals/mixtures, and effects on the dimensional stability and physical-and mechanical properties of the wood. One of the impregnants was linseed oil varnish. All the impregnants were said to dimensional stability, and also were disclosed to improve certain properties of the wood.
Pizzi, A.,
A New Approach To Non
-
Toxic, Wide
-
Spectrum, Ground
-
Contact Wood Preservatives. Part I. Approach And Reaction Mechanisms,
H
OLZFORSCHUNG
Vol. 47, No. 3, 1993, pp. 253-260, asserts that copper soaps, made with the carboxylic acid groups from unsaturated fatty acids of edible vegetable oils which are non-toxic (such as corn oil or sunflower oil), from resin acids of rosin which are non-toxic, and also from synthetic unsaturated polyester resins were shown in 25-year tests to have effectiveness an
Archer Kevin J.
Roos Kenneth D.
Chemical Specialties, Inc.
Kiliman Leszek
McAndrews Held & Malloy Ltd.
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