Post-press molding of man-made boards to produce contoured furni

Stock material or miscellaneous articles – Structurally defined web or sheet – Including variation in thickness

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Details

428165, 428171, 428218, 428524, 428526, B32B 330, B32B 514

Patent

active

042685656

ABSTRACT:
A cellulosic fiber containing board is molded at a temperature of at least 525.degree. F. to provide a relatively high density skin on at least one surface.
A fibrous composition, including cellulosic fibers, is consolidated to form a blank having a density of less than 35 pounds/cubic foot. The blank is then cut to a shape larger in at least two of its three dimensions than corresponding dimensions of a mold cavity when said mold is in a closed position.
Urea is then included in at least a surface layer of fibers of the blank in an amount of at least 5% based on the dry weight of the fibers contacted with urea, and thereafter the cut blank is molded to form a contoured product having a skin on at least one surface thereof, the skin defined by a thickness of material on said surface of said product having a density greater than the material on which the skin is formed.

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