Patent ID: 7074302
Filing Date: 2006-07-11
Classification: D21J

Abstract:
1. A process for forming a three-dimensional fibrous panel, comprising the steps of: providing first and second mold members each comprising a porous support plate and a plurality of rigid mold pieces attached to the support plate, the mold pieces comprising truncated 3D tapered structures and being spaced apart on the support plate to form channels between the mold pieces, the mold pieces of the second mold member having a larger cross-section and lesser taper than the mold pieces of the first mold member; depositing a fiber stock into the first mold member to cover the mold pieces, and pressing the fiber stock into the first mold member to dewater the stock through the porous support plate and densify the stock so as to form a panel having ribs as defined by the channels in the first mold member; removing the panel from the first mold member and inserting the panel into the second mold member; and pressing the panel into the second mold member to further dewater and densify the panel.