Manufacture of resin-bound fiber structure

Claim 1

THE METHOD WHICH COMPRISES DISPERSING INTO A GASEOUS MEDIUM 100 PARTS BY WEIGHT OF DRY SUBSTANTIALLY INDIVIDUALIZED CELLULOSIC FIBERS DERIVED FROM WOOD, AND ATOMIZED FOG-LIKE PARTICLES OF AN AQUEOUS ALKALI-STABILIZED SOLUTION CONTAINING ON THE ORDER OF ABOUT 7% BY WEIGHT OF DISSOLVED PHENOL-FORMALDEHYDE RESIN-FORMING SOLIDS, IN AMOUNT TO SUPPLY FROM 7 TO 25 PARTS OF SAID RESIN SOLIDS BY WEIGHT, SAID SOLUTION HAVING THE CAPACITY READILTY TO WET ANY OF SAID FIBERS AND SPREAD OVER THE SURFACES OF SAID FIBERS, THEREBY TO PROVIDE A FILM OF SAID RESIN SOLUTION ON A SO-WETTED FIBER, CAUSING SAID FIBERS AND FOG-LIKE PARTICLES TO MINGLE IN SAID GASEOUS MEDIUM AND TO PROVIDE LIQUID FILM COATINGS ON AT LEAST A MOJOR PORTION OF SAID FIBERS AND ON AT LEAST A PORTION OF THE SURFACE OF A SO-COATED FIBER, BRINGING THE RESULTING MIXTURE OF FIBERS AND CARRIED LIQUID INTO FELTED-FIBER-MAT-FORMING CONTACT WHEREBY FIBERTO-FIBER CONTACTS ARE FORMED IN THE PRESENCE OF LIQUID CARRIED INITIALLY BY AT LEAST ONE OF ANY TWO CONTACTING FIBERS, AND DRYING THE RESULTING MAT AT A THERMOSETTING TEMPERATURE FOR SAID RESIN BEFORE SATURATING IMPREGNATION OF THE FIBERS CAN OCCUR, WHEREBY TO PROVIDE RESIN-BONDS FROM FIBER-TOFIBER AND RESIN COATS ON AT LEAST SOME OF THE SURFACES OF THE FIBERS.

Claim 2

THE METHOD WHICH COMPRISES DISPERSING INTO A GASEOUS MEDIUM 100 PARTS BY WEIGHT OF DRY SUBSTANTIALLY INDIVIDUALIZED CELLULOSIC FIBERS DERIVED FROM WOOD, AND ATOMIZED FOG-LIKE PARTICLES OF AN AQUEOUS ALKALI-STABILIZED SOLUTION CONTAINING ON THE ORDER OF ABOUT 7% BY WEIGHT OF DISSOLVED PHENOL-FORMALDEHYDE RESIN-FORMING SOLIDS, IN AMOUNT TO SUPPLY FROM 7 TO 25 PARTS OF SAID RESIN SOLIDS BY WEIGHT, SAID SOLUTION HAVING THE CAPACITY READILTY TO WET ANY OF SAID FIBERS AND SPREAD OVER THE SURFACES OF SAID FIBERS, THEREBY TO PROVIDE A FILM OF SAID RESIN SOLUTION ON A SO-WETTED FIBER, CAUSING SAID FIBERS AND FOG-LIKE PARTICLES TO MINGLE IN SAID GASEOUS MEDIUM AND TO PROVIDE LIQUID FILM COATINGS ON AT LEAST A MOJOR PORTION OF SAID FIBERS AND ON AT LEAST A PORTION OF THE SURFACE OF A SO-COATED FIBER, BRINGING THE RESULTING MIXTURE OF FIBERS AND CARRIED LIQUID INTO FELTED-FIBER-MAT-FORMING CONTACT WHEREBY FIBERTO-FIBER CONTACTS ARE FORMED IN THE PRESENCE OF LIQUID CARRIED INITIALLY BY AT LEAST ONE OF ANY TWO CONTACTING FIBERS, AND DRYING THE RESULTING MAT AT A THERMOSETTING TEMPERATURE FOR SAID RESIN BEFORE SATURATING IMPREGNATION OF THE FIBERS CAN OCCUR, WHEREBY TO PROVIDE RESIN-BONDS FROM FIBER-TOFIBER AND RESIN COATS ON AT LEAST SOME OF THE SURFACES OF THE FIBERS.