Method and apparatus for forming narrow channels in a wood flake article, and the resulting article

A method of molding a three dimensionally curved article formed from binder coated wood flakes, said article having at least one relatively narrow, channel-shaped projection projecting from its surface, comprising:

• providing upper and lower mold dies, one of said dies having at least one relatively narrow channel defined therein, for forming a relatively narrow channel-shaped projection in said article;
• placing within said relatively narrow channel at least one binder coated implant having sufficient length, width, and height to substantially fill said narrow channel;
• forming a loosely felted mat of said wood flakes;
• depositing said mat onto said lower mold die;
• compressing and heating said mat between said upper mold die and said lower mold die to form said article to help force binder coated wood flakes down into said channel and onto said implant, and bind said flakes to said implant.