Patent ID: 8852485
Filing Date: 2014-10-07
Classification: B27N,B29C,B29K

Abstract:
1. A method for the dry-formation of a uniformly strong deep drawn, three-dimensional single-ply wood fiber structural core for use in making a panel having thin-board face panels, which comprises: providing a preformed, substantially flat, dry-formed single-ply mat of wood fibers having a moisture content in a range of 8 weight % to 16 weight %; providing a three-dimensional mold which comprises laminating platforms, load-bearing diagonal elements, anticline protrusions having ridges, fillets and curved corners to facilitate fiber draw during the molding process at the intersection of the laminating platforms and load-bearing diagonal elements, the longitudinal dimensions of adjoining ridges being alternatively shorter and longer to eliminate any uninterrupted straight and clear line of sight along a transverse row of adjoining ridges or valleys formed by the intersection of syncline indentations and anticline protrusions with the horizontal plane of the ridges; introducing the precompressed dry-formed single-ply mat of wood fibers into the three-dimensional mold; and drawing and molding the precompressed dry-formed single-ply mat of wood fibers into said uniformly strong three-dimensional single-ply wood fiber structural core in a substantially single pressing motion, wherein the single-ply core has a depth in the vertical axis of about ½″ up to about 1½″, wherein the panel produced by attaching thin-board face panels to the outer surfaces of said single-ply core have a Flat Crush strength which is at least about two times greater than a Flat Crush strength of wet-formed panels at equivalent weights and thicknesses.