Patent ID: 8696958
Filing Date: 2014-04-15
Classification: B27N,B32B,Y10T

Abstract:
1. A molded composite manufacturing process for producing solid core molded planar objects 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 small irregularly shaped 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 coarser irregularly shaped particles of said byproducts which will pass a screen of from about 8 to about 20 Tyler mesh but not 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 small 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 between said molds to a predetermined final thickness, 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 for a time effective to cure said composite materials.