Apparatus for introducing an additive to a composite panel

Abstract

A method of forming a composite panel includes the steps of supplying a material to a forming station, supplying a dry additive to the material at the forming station, producing a mat comprising the material and the additive, and applying heat and pressure to the mat to produce a composite panel. An apparatus for forming a composite panel includes a reservoir of raw material and at least one forming station configured to form a mat of the raw material. A dry material dispensing assembly introduces an additive to the forming station, and press applies heat and pressure to transform the mat into a panel.

1 . A method of forming a composite panel comprising the steps of: 
 supplying a material to a forming station;    supplying a dry additive to the material at the forming station;    producing a mat comprising the material and the additive; and    applying heat and pressure to the mat to produce a composite panel.    
     
     
         2 . The method of  claim 1 , wherein the material comprises wood elements.  
     
     
         3 . The method of  claim 2 , wherein the wood elements comprise strands of wood.  
     
     
         4 . The method of  claim 1 , wherein the additive is a binder.  
     
     
         5 . The method of  claim 4 , wherein the binder is a resin.  
     
     
         6 . The method of  claim 1 , wherein the forming station includes a plurality of doffing rolls, the additive being supplied to the material at the doffing rolls.  
     
     
         7 . The method of  claim 1 , wherein the dry additive is supplied to the forming station by a dry material application assembly.  
     
     
         8 . The method of  claim 7 , wherein the dry material application assembly comprises a fluidized bed and a pumping assembly.  
     
     
         9 . The method of  claim 1 , wherein the panel comprises oriented strand board.  
     
     
         10 . The method of  claim 1 , wherein the additive comprises wax.  
     
     
         11 . The method of  claim 1 , wherein the additive comprises a fire retardant.  
     
     
         12 . A method of forming a composite panel comprising the steps of: 
 supplying wood elements to a forming station;    adding a dry binder to the wood elements at the forming station;    producing a mat comprising the wood elements and the binder; and    applying heat and pressure to the mat to form a composite panel.    
     
     
         13 . The method of  claim 12 , wherein the wood elements are strands of wood and the panel is an oriented strand board.  
     
     
         14 . The method of  claim 12 , wherein the binder comprises a resin.  
     
     
         15 . The method of  claim 14 , wherein the resin is a spray dried phenolic resin.  
     
     
         16 . The method of  claim 12 , wherein the forming station includes a plurality of doffing rolls, the binder being supplied to the material at the doffing rolls.  
     
     
         17 . The method of  claim 12 , wherein the binder is supplied to the forming station by a dry material application assembly.  
     
     
         18 . An apparatus for forming a composite panel comprising, in combination: 
 a reservoir of raw material;    at least one forming station configured to form a mat of the raw material;    a dry material dispensing assembly to introduce an additive to the forming station; and    a press to apply heat and pressure to transform the mat into a panel.    
     
     
         19 . The apparatus of  claim 18 , further comprising a conveying assembly to transfer the mat from the forming station to the press.  
     
     
         20 . The apparatus of  claim 18 , wherein the dry material dispensing assembly comprises a fluidized bed and a pumping assembly.  
     
     
         21 . The apparatus of  claim 20 , wherein the pumping assembly includes a plurality of pumps connected to a header, and a plurality of conduits connected to the header to carry the additive to the at least one forming station.  
     
     
         22 . The apparatus of  claim 18 , wherein each forming station includes a plurality of doffing rolls to distribute the raw material.  
     
     
         23 . The apparatus of  claim 22 , wherein the dry material dispensing assembly is configured to introduce the additive at the doffing rolls.  
     
     
         24 . An apparatus for forming oriented strand board comprising, in combination: 
 a reservoir of wood strands;    at least one forming station to form a mat out of the wood strands;    a plurality of doffing rolls housed in each forming station and configured to present a substantially uniform flow of the wood strands as the mat is formed;    a dry material dispensing assembly to introduce an additive at the doffing rolls; and    a conveying assembly to transfer the mat to a press that includes a heat source and a pressure source configured to form a panel of oriented strand board from the mat.    
     
     
         25 . The apparatus of  claim 24 , wherein the additive is a powdered material.  
     
     
         26 . The apparatus of  claim 24 , wherein the additive is a resin.  
     
     
         27 . The apparatus of  claim 24 , wherein the dry material dispensing assembly includes a fluidized bed and a pumping assembly.  
     
     
         28 . The apparatus of  claim 27 , wherein the pumping assembly includes a plurality of pumps connected to a header, and a plurality of conduits connected to the header to carry the additive to the doffing rolls.