Patent ID: 6764625
Filing Date: 2004-07-20
Classification: B27N,B29K

Abstract:
In a method for the preparation of a consolidated wood fiber article useful as a core component for a structural member, comprising the steps of:(a) combining refined wood fibers and a binder resin and compressing the fibers and binder resin together sufficiently to form a pre-form mat having opposed major surfaces and having sufficient structural integrity to place the pre-form into a mold cavity; (b) placing the pre-form from step (a) into a mold cavity shaped to form at least one interior depression into at least one major surface of the pre-form; (c) compressing the pre-from in said cavity under elevated temperature to cure said binder resin and consolidate said cellulosic material into a structurally sound core component, wherein at least one of said major surfaces includes at least one interior depression formed in the mold cavity, said depression projecting inwardly from said major surface; and (d) removing said core component from said mold cavity; the improvement comprising: providing, before step (c), added moisture in at least a surface layer of the pre-form that is molded to include said depression, such that the pre-form placed in the mold cavity contains at least 2% by weight more moisture in a depression-receiving surface layer than at a center of the thickness of the pre-form, based on the dry weight of the pre-form, said surface layer defined as the surface 10% of the thickness of the pre-form.