Patent ID: 9056444
Filing Date: 2015-06-16
Classification: B27N,B32B,Y10T

Abstract:
1. Solid core molded planar objects produced by a composite manufacturing process employing a compression method of forming said planar objects between two molds using composite materials comprising mixtures of particles and/or fibers prepared from agricultural or forest byproducts and thermo-set resins, comprising the steps of: preparing and applying a first face layer of a first composite material comprising from about 10 to about 60 percent by weight of a thermo-set molding resin and from about 40 to about 90 percent by weight of dried fine particles of said byproducts which have passed a screen of from about 35 to about 60 Tyler mesh by applying the first face layer composite material over a first mold at a controlled application rate in the range of from about 0.2 to about 0.7 pounds of material per square foot, preparing and applying a core layer comprising a composite material comprising from about 5 to about 20 percent by weight of a thermo-set binding resin and from about 80 to about 95 percent by weight of dried coarser particles of said byproducts which will pass a screen of from about 8 to about 20 Tyler mesh but will not pass a screen of from about 35 to about 60 Tyler mesh at a controlled application rate in the range of from about 1.5 to about 6 pounds of material per square foot to cover said first face layer, preparing and applying a second face layer comprising from about 10 to about 60 percent by weight of said thermo-set molding resin and from about 40 to about 90 percent by weight of said fine particles at a controlled application rate in the range of from about 0.2 to about 1.5 pounds of material per square foot to cover said core layer, then placing a second mold over said first mold and said face and core layers to contain and compress the layers of composite materials, and heating said molds to a temperature in the range of from about 210 to about 410 degrees F. while compressing said layers between said molds at a pressure in the range of from about 300 to about 900 psi to a predetermined final thickness and holding for a time effective to cure said composite materials, including said core layer, to form smooth, hard surfaces that are absent of any surface voids and ready to be primed and painted or powder-coated without the need for sanding or other surface preparation.