TECHNICAL FIELD

[0001 ] In general, the present invention pertains to the art of environmental science and sustainable techniques of recycling low-grade wooden waste. In particular, the invention relates to industrial systems, processes and plants for recycling low-grade wooden waste and manufacturing a composite end-product therefrom.

BACKGROUND ART

[0002] It is believed that the current state of the art is represented by the following patent literature: US10086531 , US10399245, US2021086396, US20200369888, WO9613368, WO2019222490, KR101932004, KR1021 14579, KR20000002964, KR20110080568, KR20110131883, EP3296073, JPH10235621 , JP3680172, JP3662242, CN102229159.

[0003] US10086531 discloses a resilient MDF, HDF or particleboard material prepared by pressing natural fibers, which have been pre-treated with binder, to form a fiber board material. The fiber board of US10086531 is a mixture of fibers, and a resin system comprising an isocyanate, and a polyol component. The resin system in US10086531 is selected to provide are resilient material that provides sound attenuating properties.

[0004] WO2019222490 discloses a wood composite article including a plurality of wood pieces and an adhesive system disposed on or dispersed among the plurality of wood pieces for bonding the plurality of wood pieces. The adhesive system in WO2019222490 includes a binder component and a fiber component. The binder component of WO2019222490 comprises a thermosetting plastic component such as unsaturated polyesters, epoxy, polyurea, polyurethane or combinations thereof, including for example, an isocyanate compound and an isocyanate-reactive component. The composite article of WO2019222490 may be formed into various objects such as railroad ties, fencing and the like.

[0005] US20200369888 discloses methods and printing inks comprising wood chips/wood powder and plant-extracted natural binders for constructing wood 3D structures.

SUMMARY OF THE INVENTION

[0006] The following summary of the invention is provided in order to provide a basic understanding of some aspects and features of the invention. This summary is not an extensive overview of the invention and as such it is not intended to particularly identify key or critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some concepts of the invention in a simplified form as a prelude to the more detailed description that is presented below.

[0007] The invention was made in view of the deficiencies of the prior art and provides systems, methods and processes for overcoming these deficiencies. According to some embodiments and aspects of the present invention, there is provided a process of manufacturing structured composite end-products, from a low-grade wooden waste. According to some embodiments of the present invention, the process of manufacturing structured composite end-products, from a low-grade wooden waste comprises providing a low-grade wooden waste, in which the low-grade wooden waste including: a Grade A wooden waste, Grade B wooden waste and Grade C wooden waste; grinding the low-grade wooden waste into a fine particulate matter; adding at least one functional additive to the fine particulate matter, in which at least one functional additive including an oil, hydrophobic material and oily substance; mixing the fine particulate matter with at least one functional additive, until formation of a homogenous precursor mixture; adding a thermosetting adhesive component configured for bonding of the precursor mixture, in which the thermosetting adhesive including at least one thermosetting epoxy resin; mixing the precursor mixture with the thermosetting adhesive, until formation of a substrate mixture; homogenizing of the substrate mixture, until formation of a homogenized substrate mixture; providing a mold for a composite wooden end-product, in which the mold embodies a structured shape including at least one exterior face; covering at least one exterior face of the mold with an in-mold coating substance; filling the mold with the homogenized substrate mixture; exerting a pressing force onto the homogenized substrate mixture whilst within the mold; heating the homogenized substrate mixture within the mold, for a predetermined period of time, whilst exerting the pressing force, until the homogenized substrate mixture hardens; thereby curing the homogenized substrate mixture by thermosetting of the adhesive; recovering a resulting rigid structured composite end-product, including an inmold coating on at least one exterior face thereof, from the mold.

[0008] In accordance with some aspects and embodiments of the present invention, there is provided a process, in which the in-mold coating comprises a gel coat, serving as a decorative coating and mechanical properties enhancer.

[0009] In accordance with some aspects and embodiments of the present invention, there is provided a process, in which the in-mold coating comprises a gel coat, in which the gel coat is epoxy based and applied in at least two layers.

[0010] In accordance with some aspects and embodiments of the present invention, there is provided a process, in which the type of the wooden waste comprises at least one member including a clean solid wood, treated solid wood, particleboard, medium density fiberboard, plywood, oriented strand board.

[001 1 ] In accordance with some aspects and embodiments of the present invention, there is provided a process, in which at least one functional additive comprises vegetable oils, palm oil, castor oil.

[0012] In accordance with some aspects and embodiments of the present invention, there is provided a process, in which a ratio of a weight of the low-grade wooden waste to the thermosetting epoxy resin is about 3 to 1 respectively.

[0013] In accordance with some aspects and embodiments of the present invention, there is provided a process, in which the epoxy resin comprises epoxy grade EPC 304 of EP 71 Epoxy system.

[0014] According to some embodiments and aspects of the present invention, there is provided a composite wooden end-product with in-mold coating, manufactured from a low-grade wooden waste. According to some embodiments of the present invention, the composite wooden end-product with in-mold coating, manufactured from a low-grade wooden waste comprises a structured shape including at least one exterior face; in-mold coating covering at least one exterior face thereof.

[0015] According to some embodiments of the present invention, the composite wooden end-product is being manufactured by performing the steps of: providing a low- grade wooden waste, in which the low-grade wooden waste including a Grade A wooden waste, Grade B wooden waste and Grade C wooden waste; grinding the low-grade wooden waste into a fine particulate matter; adding at least one functional additive to the fine particulate matter, in which at least one functional additive including an additive including an oil, hydrophobic material and oily substance; mixing the fine particulate matter with at least one functional additive, until formation of a homogenous precursor mixture; adding a thermosetting adhesive component configured for bonding of the precursor mixture, in which the thermosetting adhesive including at least one thermosetting epoxy resin; mixing the precursor mixture with the thermosetting adhesive, until formation of a substrate mixture; homogenizing of the substrate mixture, until formation of a homogenized substrate mixture; providing a mold for the composite wooden end-product, in which the mold embodies a structured shape including at least one exterior face; covering at least one exterior face of the mold with an in-mold coating substance; filling the mold with the homogenized substrate mixture; exerting a pressing force onto the homogenized substrate mixture whilst within the mold; heating the homogenized substrate mixture within the mold, for a predetermined period of time, whilst exerting the pressing force, until the homogenized substrate mixture hardens; thereby curing the homogenized substrate mixture by thermosetting of the adhesive; recovering a resulting rigid structured composite end-product, including an inmold coating on at least one exterior face thereof, from the mold. -

[0016] According to some embodiments and aspects of the present invention, there is provided a system for manufacturing wooden composite products, utilizing a low-grade wooden waste. According to some embodiments of the present invention, system for manufacturing wooden composite products, utilizing a low-grade wooden waste comprises a low-grade wooden waste source container, in which the low-grade wooden waste including a Grade A wooden waste, Grade B wooden waste and Grade C wooden waste; a grinder grinding the low-grade wooden waste into a fine particulate matter; at least one functional additive container, in which at least one functional additive including an oil, hydrophobic material and oily substance; a first mixer operationally connected to the grinder and to at least one functional additive container, configured for receiving the fine particulate matter and at least one functional additive and mixing the fine particulate matter with at least one functional additive, until formation of a homogenous precursor mixture; at least one thermosetting adhesive component container, in which thermosetting adhesive component is configured for bonding of the precursor mixture, in which the thermosetting adhesive including at least one thermosetting epoxy resin; a second mixer operationally connected to the first mixer and to at least one thermosetting adhesive component container, configured for receiving the precursor mixture and at least one thermosetting adhesive component and mixing the homogenous precursor mixture with the thermosetting adhesive, until formation of a substrate mixture; a homogenizer operationally connected to the second mixer, configured for receiving the substrate mixture and homogenizing the substrate mixture, until formation of a homogenized substrate mixture; a molding machine operationally connected to the homogenizer.

[0017] According to some embodiments of the present invention, the molding machine comprises: at least one mold for a composite wooden end-product, in which the mold embodies a structured shape including at least one exterior face; at least one in-mold coating substance container; an in-mold coating applying subsystem operationally connected to the at least one in-mold coating substance container and the mold, configured for covering at least one exterior face of the mold with the in-mold coating substance; a press configured for exerting a pressing force onto the homogenized substrate mixture whilst within the mold; a heater module, configured for heating the homogenized substrate mixture within the mold, for a predetermined period of time, until the homogenized substrate mixture hardens; thereby curing the homogenized substrate mixture by thermosetting of the adhesive; a recovering mechanism, configured for recovering a resulting rigid structured composite end-product, including an in-mold coating on at least one exterior face thereof, from the mold.

DEFINITIONS

[0018] The terms "grade" and "wood waste grade", as mentioned herein, are to be interpreted per standards prescribed by the “Classification of waste wood and suitable uses”, published in Regulatory Guidance Note RGN2, by the Environment Agency of the UK on 1 Sept 2014. An example of the “Classification of waste wood and suitable uses” is available at the following URL (page 3 and 4): Waste ■■WQQd I dieting

According to the Environment Agency, different grades of wooden waste are set forth infra in TABLE 1 :

TABLE 1

Grade Definition, Examples

Visibly ‘clean’ recycled waste wood mainly from packaging waste, scrap pallets, packing cases and cable drums, and process off-cuts from the manufacture of Grade A untreated products. It is our understanding that ‘single use’ packaging and pallet manufactured within the UK are unlikely to have been subject to any form of treatment.

May contain Grade A wood together with other waste wood sourced from construction and demolition activities, transfer stations, civic amenity sites and Grade B the manufacture of furniture from solid wood.

Grade B waste wood should be regarded as treated waste wood and can mainly be used in panel board manufacture.

Grade C May contain the above grades of waste wood and from similar sources, but will predominantly consist of panel products such as panel board, MDF, plywood, including products bonded using heat treatment.

Grade C waste wood is treated waste wood and should be used as biomass fuel at Waste Incineration Directive (WID) compliant facilities and is not therefore suitable for U4 - Burning as fuel in a small appliance.

Is a hazardous waste consisting of wood which has had copper, chrome, Grade D arsenic (CCA) treatment or creosote applied. It can only be disposed of by incineration or hazardous waste landfill.

[0019] The term Oriented Strand Board (OSB) as referred to herein is to be construed as a material made out of large wood shavings glued together with resins and wax applying high heat and pressure.

[0020] The term Medium Density Fiberboard (MDF) as referred to herein is to be construed as an engineered wood product made out of lignocellulosic fibers, which are blended with resins and hot-pressed into panel shape.

[0021 ] The term Grade C, as defined hereinabove, includes any polymer laminated MDF boards, as well as any other wooden waste containing a considerable amount of non- wooden materials, such as adhesives and laminates.

[0022] The term EPC 304 of EP 71 Epoxy system, as referred herein, includes Low Viscosity Semi-flexible Room Temperature Curing Epoxy, EP 71 /EPC 304IP 2, obtainable from Polymer Gvulot Ltd. Kibbutz Gvulot, 85525 ISRAEL, the datasheet of which is available at the following URL: www.polymer-g.com/wp-content/uploads/EP71 -EPC304IP2.pdf

[0023] The terms matching and/or matchable as referred to herein is to be construed as a cross-sectional area and/or shape of a component is equal or essentially similar to a cross-sectional area and/or shape of another component. It should be acknowledged that the component need only to be similar in the cross-sectional areas and/or shapes, to satisfy the term matching/matchable, so long as the cross-sectional areas can be mated or the combination will fit into and/or occupy essentially the same lateral space.

[0024] The term structured as referred to herein is to be construed as including any geometrical shape, exceeding in complexity a plain linear shape or a shape embodying simple cylindrical, elliptical or polygonal contour or profile. A more complex shape, a plain linear shape or a shape embodying simple cylindrical, elliptical or polygonal contour or profile, constitutes an example of structured geometry.

[0025] The term modular, as referred to herein, should be construed as a stand-alone unit. The term modular inter alia means a standardized unit that may be conveniently installed or deployed without significant impact to the environment. The term modular, however, doesn’t necessarily means providing for ease of interchange or replacement. The term modular is optionally satisfied by providing for ease of at least onetime deployment or installation.

[0026] By "operationally connected" and "operably coupled" or similar terms used herein is meant connected in a specific way (e.g., in a manner allowing fluid to move and/or electric power to be transmitted) that allows the disclosed system and its various components to operate effectively in the manner described herein.

[0027] The terms firm rigid, or stiff, as referred to herein, are to be construed as having rigidity modulus value, otherwise referred to as the shear modulus, of 4800 MPa or more. Materials are considered to be firm rigid, or stiff but not tensile, when such materials are incapable of being efficiently elastically flexed or bent. Stiff materials, such as steel, are defined as having rigidity modulus value well exceeding 4800 MPa.

[0028] The terms pliable or pliant, as referred to herein, are to be construed as having high tensile strength and capable of being efficiently elastically flexed or bent but not being resilient and incapable of being efficiently stretched or expanded. The term tensile or tensile strength, as referred to herein, is to be construed inter alia as a shortcut of the known term ultimate tensile strength, frequently represented acronym as UTS, meaning an intensive property of a material or structure to withstand loads tending to elongate, namely to resist tension, defined as the maximum stress that a material can withstand while been stretched or pulled before sustaining breaking, substantial deformation and/or necking before fracture, such as nylon, relating to essentially non-ductile materials, having UTS value ranging between about 600 and 1000 MPa or more, but not including rigid, firm or stiff materials.

[0029] In the specification or claims herein, any term signifying an action or operation, such as: a verb, whether in base form or any tense, gerund or present/past participle, is not to be construed as necessarily to be actually performed but rather in a constructive manner, namely as to be performed merely optionally or potentially.

[0030] The term “substantially” as used herein is a broad term, and is to be given its ordinary and customary meaning to a person of ordinary skill in the art (and is not to be limited to a special or customized meaning), and refers without limitation to being largely but not necessarily entirely of that quantity or quality which is specified.

[0031 ] The term "essentially" means that the composition, method or structure may include additional ingredients, stages and or parts, but only if the additional ingredients, the stages and/or the parts do not materially alter the basic and new characteristics of the composition, method or structure claimed.

[0032] As used herein, the term “essentially” changes a specific meaning, meaning an interval of plus or minus ten percent (± 10%). For any embodiments disclosed herein, any disclosure of a particular value, in some alternative embodiments, is to be understood as disclosing an interval approximately or about equal to that particular value (i.e., ± 10%).

[0033] As used herein, the terms “about” or “approximately” modify a particular value, by referring to a range equal to the particular value, plus or minus twenty percent (+1-20%). For any of the embodiments, disclosed herein, any disclosure of a particular value, can, in various alternate embodiments, also be understood as a disclosure of a range equal to about that particular value (i.e. +/-20%).

[0034] As used herein, the term “or” is an inclusive “or” operator, equivalent to the term “and/or,” unless the context clearly dictates otherwise; whereas the term “and” as used herein is also the alternative operator equivalent to the term “and/or,” unless the context clearly dictates otherwise.

[0035] It should be understood, however, that neither the briefly synopsized summary nor particular definitions hereinabove are not to limit interpretation of the invention to the specific forms and examples but rather on the contrary are to cover all modifications, equivalents and alternatives falling within the scope of the invention.

DESCRIPTION OF THE DRAWINGS

[0036] The present invention will be understood and appreciated more comprehensively from the following detailed description taken in conjunction with the appended drawings in which:

[0037] FIG 1A is a flowchart of process of manufacturing structured composite endproducts from a low-grade wooden waste, according to some embodiments of the present invention;

[0038] FIG 1 B is a flowchart of process of manufacturing structured composite endproducts from a low-grade wooden waste, according to some embodiments of the present invention;

[0039] FIG 2A is a perspective view of a composite wooden end-product with in-mold coating, manufactured from a low-grade wooden waste, according to some embodiments of the present invention;

[0040] FIG 2B is a perspective view of the frontal panel of the composite wooden end-product with in-mold coating manufactured from a low-grade wooden waste, according to some embodiments of the present invention; [0041 ] FIG 3 is a schematic block diagram showing a system for manufacturing wooden composite products, utilizing a low-grade wooden waste, according to some embodiments of the present invention.

[0042] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown merely by way of example in the drawings. The drawings are not necessarily complete and components are not essentially to scale; emphasis instead being placed upon clearly illustrating the principles underlying the present invention.

DETAILED DISCLOSURE OF EMBODIMENTS

[0043] Illustrative embodiments of the invention are described below. In the interest of clarity, not all features of actual implementation are described in this specification. It should be appreciated that various features or elements described in the context of some embodiment may be interchangeable with features or elements of any other embodiment described in the specification. Moreover, it will be appreciated that for the development of any actual embodiment, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with technology- or business- related constraints, which may vary from one implementation to another, and the effort of such a development might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure. [0044] In accordance with some embodiments of the present invention, reference is now made to FIG 1A and FIG 1B, showing a flowchart of process 10 of manufacturing structured composite end-products from a low-grade wooden waste. The embodiment of process 10 shown in FIG 1A and FIG 1 B illustrates various features that may be interchangeable with elements and/or any other embodiment described in the specification. [0045] Process 10 typically comprises initial step 12 of providing a low-grade wooden waste. In some embodiments, the low-grade wooden waste comprises wood waste of: Grade A, Grade B and Grade C wood waste. In some examples, the low-grade wooden waste is a clean solid wood, treated solid wood, particleboard, medium density fiberboard, plywood, oriented strand board, etc.

[0046] In some embodiments, process 10 further proceeds to step 14 of grinding the low-grade wooden waste into a fine particulate matter. In some embodiments, process 10 further includes step 16 of adding at least one functional additive to the fine particulate matter. In some embodiments, at least one functional additive container in a non-limiting manner includes: an oil, hydrophobic material and oily substance. In some examples, the at least one functional additive inter alia includes: vegetable oils, palm oil and/or castor oil.

[0047] In some embodiments, process 10 further includes step 18 of mixing the fine particulate matter with at least one functional additive, until formation of a homogenous precursor mixture. In some embodiments, process 10 further proceeds to step 20 of adding a thermosetting adhesive component configured for bonding of the precursor mixture. In some embodiments, the thermosetting adhesive component comprises at least one thermosetting epoxy resin. In some examples, at least one thermosetting epoxy resin comprises epoxy grade EPC 304 of EP 71 Epoxy system.

[0048] In some examples, a ratio of a weight of the low-grade wooden waste to the volume thermosetting epoxy resin is about 3 to about 1 respectively. This ratio of about 3 to about 1 is configured to provide a good balance between mechanical properties of and uniformity of the epoxy distribution in the structured composite end-product.

[0049] In some embodiments, process 10 further includes step 22 of mixing the precursor mixture with the thermosetting adhesive, until formation of a substrate mixture. In some embodiments, process 10 yet further proceeds to step 24 of homogenizing of the substrate mixture, until formation of a consistent and/or homogenized substrate mixture.

[0050] In some embodiments, process 10 further proceeds to step 26 of providing a mold for a composite wooden end-product, in which the mold embodies a structured shape including at least one exterior face. In some embodiments, process 10 further includes step 28 of covering at least one face of the mold with an in-mold coating substance. In some examples, in-mold coating substance comprises a gel coat, serving as a decorative coating and mechanical properties enhancer. In some examples, the gel coat is epoxy based and applied in at least two layers.

[0051 ] In some embodiments, process 10 further includes step 30 of filling the mold with the consistent and/or homogenized substrate mixture. Process 10 typically proceeds to step 32 of exerting a pressing force onto the homogenized substrate mixture whilst within the mold.

[0052] In some embodiments, process 10 further includes step 34 of heating the homogenized substrate mixture within the mold, for a predetermined period of time, concomitantly with exerting the pressing force of step 32, until the homogenized substrate mixture hardens, thereby curing the homogenized substrate mixture by thermosetting of the adhesive. Process 10 then typically terminates with step 36 of recovering a resulting rigid structured composite end-product including an in-mold coating on at least one exterior face thereof from the mold.

[0053] In accordance with some embodiments of the present invention, reference is now made to FIG 2A and 2B showing respectively perspective view of composite wooden end-product 40 and perspective view of frontal panel 42 of composite wooden end-product 40 with in-mold coating manufactured from a low-grade wooden waste. The embodiment of composite wooden end-product 40 shown in FIG 2A and 2B illustrates various features that may be interchangeable with elements and/or any other embodiment described in the specification.

[0054] In some embodiments, composite wooden end-product 40 comprises modular frontal panel 42 embodying a structured shape. Modular frontal panel 42 comprises at least one structured exterior face 44. In some embodiments, at least one structured exterior face 44 of modular frontal panel 42 of composite wooden end-product 40 further comprises inmold coating 46. In mold-coating 46 is configured for covering at least one exterior face 44 of modular frontal panel 42.

[0055] In accordance with some embodiments of the present invention, reference is now made to FIG 3 showing system 50 for manufacturing wooden composite products, utilizing a low-grade wooden waste. The embodiment of system 50 shown in FIG 3 illustrates various features that may be interchangeable with elements and/or any other embodiment described in the specification.

[0056] In some embodiments, system 50 for manufacturing wooden composite products, utilizing a low-grade wooden waste, comprises low-grade wooden waste source container 52. In some embodiments, low-grade wooden waste source container 52 of system 50 for manufacturing wooden composite products is configured to accommodate wooden waste of low-grade, namely a grade A, grade B and/or grade C. In some examples, a mixture of A to C grades wooden waste is configured for manufacturing of interior covering surfaces and/or panels, monolithic furniture, panelboards and etc.

[0057] In some examples, the wooden waste in a non-limiting manner includes: a clean solid wood, treated solid wood, particleboard, medium density fiberboard, plywood, oriented strand board. In the manufacture of panelboards for example, types of wood with less favorable properties for the application of compact wood, such as low-grade wooden waste, industry leftovers and/or wooden byproducts are utilizable into a product with high value and excellent properties.

[0058] In some embodiments, system 50 includes grinder 54. Grinder 54 is configured for grinding the low-grade wooden waste into a fine particulate matter. In some embodiments, system 50 comprises at least one functional additive container 56. At least one functional additive container 56 is configured to accommodate at least one functional additive. In some examples, the at least one functional additive accommodated in container 56 in a non-limiting manner includes: an oil, hydrophobic material, lipophilic material and oily substance.

[0059] In some examples, the at least one functional additive accommodated in container 56 in a non-limiting manner includes: a palm oil which is an edible plant oil derived from the fruit of palm trees, castor oil and/or other vegetable oils, lipid materials extracted from plants, triglycerides. In some examples, palm oil is a green and non-harmful and is used as a plasticizer. Palm oil is optimal for integration within polymeric materials because of its molecular structure and configured for overcoming wettability and/or humidity problems and improving of the mechanical properties of the rigid structured wooden composite endproducts, manufactured from a low-grade wooden waste.

[0060] In some embodiments, system 50 comprises first mixer 58. First mixer 58 is operationally connected to grinder 54 and to at least one functional additive container 56. First mixer 58 is configured for receiving the fine particulate matter from grinder 54 and at least one functional additive from container 56, and mixing the fine particulate matter with at least one functional additive, until formation of a consistent and/or homogenous precursor mixture.

[0061 ] In some embodiments, system 50 further comprises thermosetting adhesive component container 60. Thermosetting adhesive component container 60 is configured for accommodating a thermosetting adhesive component. The thermosetting adhesive component is configured for bonding of the precursor mixture, into the rigid structured wooden composite end-products, manufactured from a low-grade wooden waste.

[0062] In some embodiments, the thermosetting adhesive component comprises at least one thermosetting epoxy resin. Using thermosetting epoxy resin as adhesive is an appropriate solution to manufacture new panelboards from low-grade wooden waste. The at least one thermosetting epoxy resin is configured to confer superb mechanical properties, of the rigid structured wooden composite end-products, manufactured from a low-grade wooden waste, due to an excellent compatibility with the chemical structure of the wooden ingredient. In some examples, the at least one thermosetting epoxy resin requires to be heated, so as to allow a sufficiently low level of viscosity to be reached, in order to be poured by the means of gravitational force. [0063] In some examples, the at least one thermosetting epoxy resin in a non-limiting manner further includes: glass, carbon, or fibers, produces composite materials with the best properties of most thermosets. In some examples, the at least one thermosetting epoxy resin comprises the EPC 304 of EP 71 Epoxy system with low volatile organic compound percentage, allowing for a safe and non-harmful process in standard factory environment.

[0064] In some embodiments, system 50 further comprises second mixer 62. Second mixer is operationally connected to first mixer 58 and to the at least one thermosetting adhesive component container 60. Second mixer 62 is configured for receiving the precursor mixture comprises first mixer 58 and at least one thermosetting adhesive component from container 60, and mixing the homogenous precursor mixture with the thermosetting adhesive, until formation of a substrate mixture. In some examples, second mixer 62 is configured for performing a shearing action on the homogenous precursor mixture and the thermosetting adhesive, breaking down the little chunks of at least one thermosetting epoxy resin in the homogenous precursor mixture, thereby facilitating an optimal homogeneity and dispersion.

[0065] In some embodiments, system 50 further comprises homogenizer 64. Homogenizer 64 is operationally connected to second mixer 62. Homogenizer 64 is configured for receiving the substrate mixture from second mixer 62 and homogenizing the substate mixture, until formation of a consistent and/or homogenized substrate mixture.

[0066] In some embodiments, system 50 further comprises molding machine 66. Molding machine 66 is operationally connected to homogenizer 64. Molding machine 66 is configured for receiving the consistent and/or homogenized substrate mixture from homogenizer 64. In some embodiments, molding machine 66 comprises at least one mold 68 for a composite wooden end-product. At least one mold 68 embodies a structured shape including at least one face.

[0067] In some embodiments, molding machine 66 further comprises in-mold coating applying subsystem 72. Molding machine 66 typically further includes at least one in-mold substance container 70. At least one in-mold substance container 70 is configured to accommodate the in-mold coating substance. In-mold coating applying subsystem 72 is operationally connected to at least one in-mold coating substance container 70 and at least one mold 68. In-mold coating applying subsystem 72 is configured for receiving the in-mold coating substance from in-mold coating container 70, and for applying the in-mold coating substance, by covering at least one face of at least one mold 68 with the in-mold coating substance. [0068] In some embodiments, molding machine 66 further comprises press 74. Press 74 is configured for exerting a pressing force onto the homogenized substrate mixture, whilst within at least one mold 68. In some embodiments, molding machine 66 further comprises heater module 76. Heater module 76 is configured for heating the homogenized substate mixture within at least one mold 68, for a predetermined period of time, until the homogenized substrate mixture hardens, thereby curing the homogenized substrate mixture by thermosetting of the adhesive.

[0069] In some embodiments, molding machine 66 further comprises recovering mechanism 78. Recovering mechanism 78 is configured for recovering a resulting rigid structured composite end-product, including an in-mold coating on at least one exterior face thereof, from at least one mold 68.

WORKING EXAMPLES

[0070] Example 1 - Preferred exemplary composition of precursor mixture

[0071 ] In one working example, it was empirically established that adding functional additive at a ratio of 5% five percent in weight to the weight of the fine particulate matter of the low-grade wooden waste has shown an optimal result in a lot of aspects of the structured composite end-product, such as mechanical properties of the structured composite endproduct, as well as processability and utilization of a non-harmful additive.

[0072] Example 2 - Preferred exemplary functional additive

[0073] In another working example, it was empirically established that using palm oil as the functional additive provided for the utilization of a green and non-harmful substance, as an efficient plasticizer. Palm oil due to its molecular structure has exhibited optimal integration within polymeric materials and provided for overcoming wettability and/or humidity problems as well as improving mechanical properties of the structured wooden composite end-product, in the shape of modular bathroom furniture cabinet, manufactured from a low-grade wooden waste.

[0074] Example 3 - Preferred exemplary composition of substrate mixture

[0075] In yet another working example, it was empirically established that the ratio of

3 to 1 of between the weight of the low-grade wooden waste to the volume thermosetting epoxy resin has exhibited an optimal balance between the mechanical properties and uniformity. [0076] Example 4 - Exemplary epoxy bonding system

[0077] In still another working example, it was empirically established that the use of thermosetting epoxy resin - EPC 304 of EP 71 Epoxy System has exhibited suitable physical properties of the structured composite end-product.

[0078] Example 5 - Exemplary epoxy bonding system

[0079] In yet another working example, it was empirically established that the Epoxy System of thermosetting epoxy resin - GC1 050, obtainable FEROCA MADRID, at Espanoleto, 1 1 28010 Madrid 914481 271 , has exhibited suitable physical properties of the structured composite end-product.

[0080] Example 6 - Exemplary parameters for the epoxy bonding system

[0081 ] In still yet another working example, it was empirically established that an epoxy bonding system that has been used with the parameters of: viscosity 13,000MPa at 25 degrees Celsius, having gel time of 60 minutes at 23 degrees Celsius and with curing time of 90 minutes at 60 degrees Celsius has yielded structured composite end-product, which exhibited suitable physical properties.

[0082] Example 7 - mechanical properties of the composite end-product

[0083] In yet still another working example, it was empirically established that GC1

050 epoxy bonding system of Example 5 that has been used with parameters of Example 6 has yielded the end-product with the following mechanical properties: hardness 88/86, flexural modulus of 4,450 MPa and flexural strength of 72 MPa.

[0084] Example 8 - Exemplary epoxy bonding system and parameters

[0085] In still yet another working example, it was empirically established that the Epoxy system of thermosetting epoxy resin - EP-170 and EPC-124 that has been used at a ratio of 3 to 1 of between the volume of the ingredient EPC-124 to the volume of the ingredient EP-170, with a gel time of 30 minutes, with curing time of 8 hours at 60 degrees Celsius or with curing time of 8 hours at 25 degrees Celsius has yielded structured composite end-product, which exhibited suitable physical properties.

[0086] Example 10 - Preferred exemplary process

[0087] In yet still another working example, it was empirically established that the low- grade wooden waste that was mixed to the castor oil by a mixer for 15 minutes, where the low-grade wooden waste was mixed with the castor oil and the Epoxy resin for 25 minutes, and where the homogenized substrate mixture was molded within a mold preheated to 120 degrees and cured for 30 minutes, has yielded structured composite end-product, which exhibited suitable physical properties.

INDEX OF REFERENCE NUMERALS

[0088] Within the specification hereinabove inter alia the following numerals were used to denote the particular constituents in the appended drawings:

[0089] 10 - manufacture process of structured composite end-products

[0090] 12 - step of providing a low-grade wooden waste

[0091 ] 14 - step of grinding the low-grade wooden waste

[0092] 16 - step of adding at least one functional additive

[0093] 18 - step of mixing a homogenous precursor mixture

[0094] 20 - step of adding a thermosetting adhesive component

[0095] 22 - step of mixing precursor mixture with thermosetting adhesive

[0096] 24 - step of homogenizing consistent substrate mixture

[0097] 26 - step of providing a mold for a composite wooden end-product

[0098] 28 - step of covering at least one exterior face of the mold

[0099] 30 - step of filling the mold with the homogenized substrate mixture

[0100] 32 - step of exerting a pressing force onto the substrate mixture

[0101 ] 34 - step of heating the homogenized substrate mixture

[0102] 36 - step of recovering a rigid structured composite end-product

[0103] 40 - composite wooden end-product shaped as bathroom cabinet

[0104] 42 - frontal panel with structured shape

[0105] 44 - exterior face

[0106] 46 - in-mold coating

[0107] 50 - system for manufacturing wooden composite products

[0108] 52 - low-grade wooden waste source container

[0109] 54 - grinder

[0110] 56 - functional additive container

[0111 ] 58 - first mixer

[0112] 60 - thermosetting adhesive component container

[0113] 62 - second mixer

[0114] 64 - homogenizer

[0115] 66 - molding machine

[0116] 68 - mold

[0117] 70 - in-mold substance container [0118] 72 - in-mold coating applying subsystem

[0119] 74 - press

[0120] 76 - heater module

[0121 ] 78 - recovering mechanism [0122] It will be appreciated by persons skilled in the art of the invention that various features and/or elements elaborated in the context of a specific embodiment described hereinabove and/or referenced herein and/or illustrated by a particular example in a certain drawing enclosed hereto, whether method, system, device or product, is/are interchangeable with features and/or elements of any other embodiment described in the specification and/or shown in the drawings.

[0123] Moreover, skilled persons would appreciate that the present invention is not limited by what has been particularly shown and described hereinabove. Rather the scope of the invention is defined by the claims which follow: