Thomas E Ruffin

US Patent:

6471897, Oct 29, 2002

Filed:

Oct 20, 1999

Appl. No.:

09/420737

Inventors:

John Peter Walsh - St. Charles IL
Allen R. Hill - Laurel MS
Thomas M. Ruffin - Laurel MS

Assignee:

Masonite Corporation - Tampa FL

International Classification:

B27N 320

US Classification:

264109, 264122, 4285371

Abstract:

Disclosed herein is a cellulosic composite article and steam injection press methods of making the same by combining a phenolic resin with cellulosic material to form a mixture and, thereafter, providing a catalyzing agent, such as aluminum chloride, to the mixture. As an alternative, the method may include the steps of combining a catalyzing agent with a cellulosic material to form a mixture and, thereafter, providing a phenolic resin to the mixture. The method further includes the steps of forming a mat from the catalyzing agent-containing mixture and consolidating the catalyzing agent-containing mat in a pressing apparatus under heat, steam, and pressure to form the consolidated cellulosic product.