Molded thin-layer lignocellulosic composites made using hybrid poplar and methods of making same
Thin-layer lignocellulosic composites made using hybrid poplar and methods for the manufacture of such thin-layer composites are disclosed. Also described is a process for making thin-layer lignocellulosic composite door skins using hybrid poplar wood fiber.
1 . A thin-layer lignocellulosic composite comprising hybrid poplar (hybrid Populus ) fiber, a resin, a release agent that will not interfere with processing of the thin-layer lignocellulosic composite, and at least one type of wax.
2 . The thin-layer composite of claim 1 , wherein the thin-layer composite comprises a door skin.
3 . The thin-layer composite of claim 1 , wherein the hybrid poplar fiber comprises the total lignocellulose fiber used in the thin-layer composite.
4 . The thin-layer composite of claim 1 , wherein the hybrid poplar fiber ranges from about 40% to about 75% of the total lignocellulose fiber used in the thin-layer composite.
5 . The thin-layer composite of claim 1 , wherein the hybrid poplar fiber ranges from about 40% to about 55% of the total lignocellulose fiber used in the thin-layer composite.
6 . The thin-layer composite of claim 1 , wherein the total lignocellulose fiber ranges from about 80% to about 95% by weight of the thin-layer composite.
7 . The thin-layer composite of claim 1 , comprising a final content of about 90 to 95% lignocellulose fiber, and about 5 to 10% resin.
8 . The thin-layer composite of claim 1 , wherein the release agent is an internal release agent.
9 . The thin-layer composite of claim 1 , further comprising a pre-press sealer.
10 . The thin-layer composite of claim 1 , further comprising a final density ranging from about 45 pounds per cubic foot to about 58 pounds per cubic foot.
11 . The thin-layer composite of claim 1 , further comprising a final density ranging from about 51 pounds per cubic foot to about 56 pounds per cubic foot.
12 . The thin-layer composite of claim 1 , further comprising a thickness ranging from about 0.05 inches to about 0.5 inches.
13 . The thin-layer composite of claim 1 , further comprising a thickness ranging from about 0.08 inches to about 0.2 inches.
14 . The thin-layer composite of claim 1 , further comprising a thickness ranging from about 0.09 inches to about 0.115 inches.