Method of manufacturing consolidated cellulosic panels with contoured surfaces and variable basis weight
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United States of America Patent
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Jun 1, 2004
Grant Date -
May 29, 2003
app pub date -
Nov 28, 2001
filing date -
Nov 28, 2001
priority date (Note) -
Expired
status (Latency Note)
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Abstract
A method and system for manufacturing a consolidated cellulosic article having first and second surfaces of a desired contour, a uniform density and variable caliper and basis weight are disclosed. The method and system employ a primary press having first and second similarly contoured platens to consolidate a mat of cellulosic material and a binding agent to a softboard having first level of density with first and second opposed sides of similar contour. A removal tool is then employed to remove cellulosic material from one or both of the first and second sides in a planar fashion. The resulting mat is then compressed a second time by a secondary press having first and second platens corresponding in shape to a higher density level while maintaining a substantially uniform caliper and basis weight.
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