Method of forming a core component
AssigneeMasonite Corporation
InventorsGeoffrey Hardwick, Henry Coghlan, John Walsh, Allen Hill
Life of this patent
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Abstract
The present invention is directed to a method of forming a molded core component. A mat formed from cellulosic fiber and resin is provided. The mat is consolidated in a first press until the resin is substantially fully cured, and then removed from the first press. The consolidated mat is then placed in a second press having a mold cavity shaped to form at least one depression in at least one of the major surfaces. The consolidated mat is reformed in the second press to form a molded core component having at least one depression in at least one of the major surfaces. The molded core component has a variable density, preferably of between about 10 lbs/ft3 and 80 lbs/ft3.
Claims21
A method of forming a core component, comprising the steps of
- providing a mat formed from cellulosic material and resin;
- consolidating the mat in a first press using heat and pressure until the resin is substantially fully cured;
- removing the consolidated mat from the first press, the consolidated mat having opposed major surfaces;
- placing the consolidated mat in a second press having a mold cavity shaped to form at least one depression in at least one of the major surfaces;
- and
- reforming the consolidated mat in the second press using heat and pressure to form a molded core component having at least one depression in at least one of the major surfaces, the molded core component having a variable density.
Dependencies are inferred from the claim text.