Method of making a finished product from a feedstock, a portland cement, and a thermosetting resin

摘要

A method of making a finished product includes the steps of (a) providing a dry feedstock selected from the group consisting of particles or fibres of a lignocellulosic material; particles of an expanded mineral; particles of a foamed set hydraulic binder; particles of an undensified silica fume or a mixture of two or more thereof; (b) mixing the feedstock with: (i) a suitable amount of a thermosetting resin in finely divided dry powder form; and (ii) a suitable amount of Portland cement in finely divided dry powder form, to give a starting material; (c) subjecting the starting material of step (b) to suitable conditions of temperature and pressure to cause the thermosetting resin to set to form a cohesive product; (d) providing to the cohesive product of step (c) water in an amount sufficient for the complete hydration of the Portland cement, while simultaneously or sequentially but before the Portland cement has set, introducing carbon dioxide into the cohesive product of step (c) to assist in the setting of the Portland cement; and (e) allowing the Portland cement to set to form the finished product. The finished product may, for example, be a board.