Patent ID: 8936699
Filing Date: 2015-01-20
Classification: A47C,B27F,B27H,B27N,B32B,D21J,E04C,E04F,Y10T

Abstract:
1. A method of molding a fiberboard panel in a predetermined three-dimensional non-planar shape, comprising the steps of: hydropulping a furnish of cellulose fiber material into a water solution and mixing to separate the fibers into a pulp; pouring the pulp onto a first surface of a perforated mold screen in a former box, the screen having opposite first and second surfaces and a shape including a plurality of protrusions corresponding to a first side of the predetermined three-dimensional panel shape; removing water from the pulp through the mold screen by applying a vacuum to the second surface of the screen to leave a wet fiber mat on the screen; removing the sides of the box and transferring the mold screen carrying the wet fiber mat into a first press between a first, perforated platen of a shape substantially corresponding to the mold screen shape including a plurality of protrusions corresponding to a first side of the predetermined three-dimensional panel shape, and a second platen of the first press, the second platen being of non-porous elastomeric material and having a second plurality of protrusions corresponding to the second side of the predetermined three-dimensional panel shape; placing the mold screen onto the first, perforated platen of the first; moving the second platen of elastomeric material into engagement with the wet fiber mat to close the first press, whereby a plurality the second plurality of protrusions extend in between the at least some of the protrusions of the first press; pressing the opposing first and second platens towards each other to squeeze the wet fiber mat between the platens and squeeze water out of the mat through the openings in the mold screen and first platen; and hot pressing the fiber mat to remove at least substantially all of the water from the mat and form a finished panel.