Resin-impregnated substrate materials

Abstract

Building materials based on polyisocyanate-impregnated lignocellulosic substrates provide increased strength and water, fire, insect, and fungi resistance compared to prior art building materials. At the same time, such building materials exhibit an aesthetically pleasing surface and can, therefore, be used in consumer visible applications (such as furniture) as well as in consumer invisible (such as door frames and stiles) applications.

What is claimed is:  
     
         1 . An building article having a smooth, low-gloss surface by (1) impregnating a lignocellulosic material with an isocyanate resin material; (2) removing excess isocyanate resin from the impregnated lignocellulosic material by impinging air at a high flow rate upon the impregnated lignocellulosic material; (3) polymerizing the resin by applying water to the impregnated lignocellulosic material, the water being at a temperature sufficient for polymerization; and (4) removing the water from the polymerized resin-impregnated lignocellulosic material.  
     
     
         2 . The building article of  claim 1 , wherein the impregnated lignocellulosic material is substantially non-conductive.  
     
     
         3 . The building article of  claim 1 , wherein the lignocellulosic material comprises material selected from the group consisting of medium density fiberboard, high density fiberboard, oriented strand board, particle board, hemp, sisal, cotton stalk, wheat, straw, bamboo, jute, salt water reeds, palm fronds, flax, groundnut shells, hard woods and soft woods.  
     
     
         4 . The building article of  claim 1 , wherein the building article comprises a veneer, sheet or panel.  
     
     
         5 . The building article of  claim 1 , wherein the building article comprises a building component.  
     
     
         6 . The building article of  claim 5 , wherein the building component comprises a door component.  
     
     
         7 . The building article of  claim 5 , wherein the building component comprises a subfloor component.  
     
     
         8 . The building article of  claim 5 , wherein the building component comprises a roofing substrate component.  
     
     
         9 . The building article of  claim 5 , wherein the building component comprises a soffit component.  
     
     
         10 . The building article of  claim 5 , wherein the building component is adapted for marine construction.  
     
     
         11 . The building article of  claim 1 , wherein the building article comprises a fence component.  
     
     
         12 . The building article of  claim 1 , wherein the building article comprises a recreational equipment component.  
     
     
         13 . The building article of  claim 1 , wherein the building article comprises a component of a sign.  
     
     
         14 . The building article of  claim 1 , wherein the building article comprises furniture.  
     
     
         15 . An article comprising a lignocellulosic substrate impregnated with a polyisocyanate material, said impregnated lignocellulosic substrate being substantially non-conductive.  
     
     
         16 . The article of  claim 15 , wherein the impregnated lignocellulosic substrate comprises a smooth, low-gloss surface.  
     
     
         17 . The article of  claim 15 , wherein the impregnated lignocellulosic substrate further exhibits increased strength over an un-impregnated lignocellulosic substrate.  
     
     
         18 . The article of  claim 15 , wherein the impregnated lignocellulosic substrate further exhibits an increased resistance to water over an un-impregnated lignocellulosic substrate.  
     
     
         19 . The article of  claim 15 , wherein the lignocellulosic substrate comprises material selected from the group consisting of medium density fiberboard, high density fiberboard, oriented strand board, particle board, hemp, sisal, cotton stalk, wheat, straw, bamboo, jute, salt water reeds, palm fronds, flax, groundnut shells, hard woods and soft woods.  
     
     
         20 . The article of  claim 15 , wherein the polyisocyanate material comprises methylene diphenyl diisocyanate or poly(methylene diphenyl diisocyanate).  
     
     
         21 . The article of  claim 15 , wherein the polyisocyanate material comprises polyisocyanate resin.  
     
     
         22 . The article of  claim 15 , wherein the lignocellulosic substrate comprises a veneer, sheet or panel.  
     
     
         23 . The article of  claim 15 , wherein the article comprises a building component.  
     
     
         24 . The article of  claim 23 , wherein the building component comprises a door component.  
     
     
         25 . The article of  claim 23 , wherein the building component comprises a subfloor component.  
     
     
         26 . The article of  claim 23 , wherein the building component is adapted for marine construction.  
     
     
         27 . The article of  claim 23 , wherein the building component comprises a soffit component.  
     
     
         28 . The article of  claim 23 , wherein the building component comprises a roofing substrate component.  
     
     
         29 . The article of  claim 15 , wherein the article comprises a fence component.  
     
     
         30 . The article of  claim 15 , wherein the article comprises a recreational equipment component.  
     
     
         31 . The article of  claim 15 , wherein the article comprises a component of a sign.  
     
     
         32 . The article of  claim 15 , wherein the article comprises a furniture component.