Patent ID: 7241407

Claim:
A method for making a plate-like fiber-reinforced composite product to be used as building or packing material, the method comprising the steps of preparing a three-dimensional cohesive fiber mat of fibers bound together, the fibers having a thickness mainly ranging between 0.5 and 0.8 mm and a width between 0.3 and 2 mm, at least 80% of the fibers having a length of at least 100 mm, providing the fiber mat with a moisture content of at or below 5%, placing the fiber mat on a lower laminate, applying a foaming hardening binding agent in liquid form on the fibers of the fiber mat so that a mixture of fiber mat and binding agent is obtained wherein the fibers are surrounded by the binding agent, transferring and guiding the mixture between the lower laminate and an upper laminate between lower and upper pressing plates, said lower and upper laminate and said pressing plates being arranged to rotate endlessly at a rotation speed on an upper and, respectively a lower, side of the mixture thereby transferring the mixture at the rotation speed of the pressing plates, the mixture comprising fibers close to an upper surface thereof and close to a lower surface thereof, placing the mixture under a pressure between about 0.8 bar and about 5 bar and allowing the binding agent to foam up and expand and allowing the mixture to harden between the upper and the lower pressing plates into a hardened plate-like product having a thickness of 10 mm to 150 mm and comprising fibers close to the upper surface thereof and close to the lower surface thereof when transferring the mixture between the pressing plates, and removing the laminates from the hardened product.