Composite wood and manufacturing method thereof

Abstract

A manufacturing method of composite wood that arbitrary amount of wood can be used, nailing is possible and a product with arbitrary configuration is easily manufactured is provided. A melted binder resin and a plurality of wood pieces are kneaded. Then, a resultant kneaded material of the wood pieces and the binder resin is strongly pressed. The binder resin is cooled while the kneaded material is strongly pressed. Alternatively, strong pressing and cooling are repeated for the kneaded material. As a result, the binder resin is cured. A resultant composite wood is cut into a board with a predetermined thickness or a bar with a predetermined dimension and assembled into a desired product. A water content of the wood pieces may be evaporated by heat from the binder resin or may be evaporated by heating the wood pieces.

1 . A manufacturing method of composite wood that a plurality of wood pieces each of which has a three-dimensional configuration that a plurality of small cavities substantially remain in three vertical directions are entirely dispersed and bound together by a binder resin while being strongly pressed in at least one direction of three vertical directions, each of the plurality of wood pieces is surrounded by the binder resin with small cavities at a surface side of at least some of its three-dimensional configuration of each of the plurality of wood pieces being deformed so as to be collapsed and the binder resin enters into the small cavities at the surface side of each of the plurality of wood pieces, so that the plurality of wood pieces and the binder resin are bound together, the manufacturing method comprising the steps of: 
 heating the wood pieces such that a water content of the wood pieces is evaporated, melting the binder resin and kneading the melted binder resin and the plurality of wood pieces; and    pressing a kneaded material of the wood pieces and the binder resin in a predetermined direction, cooling the kneaded material while at least one of maintaining a pressed state and repeating said steps of pressing and cooling such that the binder resin is cured.    
   
   
       2 . The manufacturing method of composite wood according to  claim 1 , wherein when the melted binder resin and the plurality of wood pieces are kneaded, the wood pieces are heated by heat from the wood pieces binder resin in order to evaporate a water content of the wood pieces.  
   
   
       3 . The manufacturing method of composite wood according to  claim 1 , further comprising the step of crushing used composite wood into chips for use in said step of heating.