Patent ID: 7399438

Claim:
A method to produce a thin-layer lignocellulosic composite having increased resistance to moisture-induced shrinking or swelling comprising: (a) forming a lignocellulosic composite mixture comprising at least one type of lignocellulosic fiber comprising a predetermined moisture content at least 5% by weight of an organic isocyanate resin, a release agent that does not interfere with subsequent processing of the thin-layer lignocellulosic composite and at least one type of wax; (b) pre-pressing the mixture into a loose mat; and (c) pressing the mat between two dies at an elevated temperature and pressure and for a sufficient time to further reduce the thickness of the mat to form a thin-layer composite having a thickness of between about 1 and about 5 mm, and to allow the isocyanate resin to interact with the lignocellulosic fiber such that the resultant thin-layer composite has a predetermined resistance to moisture, wherein the thin-layer lignocellulosic composite comprises a molded door skin, and wherein at least one surface of at least one die is coated with an anti-bonding agent.