This invention relates to a process for making dimensionally stable
reconstituted composite products from lignocellulosic material. By
treating lignocellulose with high pressure steam to decompose and
hydrolyze the hemicellulose, cellulose and lignin fractions of the
lignocellulose and using those decomposition products as both a bonding
and bulking agent, it converts, under heat and pressure in a molding
operation, the treated lignocellulose into molded composite products such
as panel boards and molded articles. The composite products thus produced
possess good physical and mechanical properties. Specifically, the
dimensional stability in terms of the thickness swelling and linear
expansion of panel boards such as fiberboards and particleboard, can be
minimized to very low levels when the panel boards are made in high
density. The adhesive bond developed from thermosetting of the
decomposition products of hemicellulose, cellulose and lignin is strong
and stable, and resistant to boiling water and acid hydrolysis, and is
free of formaldehyde emissions. Thus, the reconstituted panel boards and
molded products are suitable for exterior and particularly for indoor
applications. The absence of free formaldehyde emissions makes the
product very suitable for interior applications. The manufacturing cost
for the reconstituted products is significantly lower in comparison to
the conventional process because expensive synthetic resin is not used.