Patent ID: 6743318
Filing Date: 2004-06-01
Classification: B27N,B29K,Y10T

Abstract:
A method for producing a consolidated cellulosic article, comprising the steps of:providing a mat of cellulosic material and binder resin; providing a first contoured front platen having a first pattern; providing a first contoured rear platen having a pattern generally corresponding to the first pattern of the front platen; consolidating the mat between the first contoured front platen and the first contoured rear platen under heat and pressure to form a molded softboard having a contoured front surface and a correspondingly contoured rear surface, the softboard having a substantially uniform density and substantially uniform caliper; removing portions of the molded softboard up to a predetermined removal plane to form a softboard having a front surface and rear surface with desired contours; providing a second contoured front platen having a contour substantially corresponding to the contour of the front surface; providing a second contoured rear platen having a contour substantially corresponding to the contour of the rear surface; and consolidating the softboard between the second contoured front platen and the second contoured rear platen, under heat and pressure.