Multi-layer composite pulp product, and system and process for manufacturing same

A process for manufacturing a multi-layer composite pulp product, the process comprising:

• fabricating a reinforcement layer;
• forming a soggy first pulp layer;
• placing the reinforcement layer on the soggy first pulp layer;
• forming a soggy second pulp layer;
• positioning the soggy second pulp layer on the reinforcement layer, wherein a precursor wet composite is defined by the soggy first pulp layer, the reinforcement layer, and the soggy second pulp layer being in a stacked configuration;
• and
• drying the precursor wet composite at a selected heating temperature and under a selected pressure.

A multi-layer composite pulp product comprising:

• a pulp layer having a lower face, an upper face disposed oppositely of the lower face, and a core pattern of opposingly-defined cavities and protrusions;
• and
• an upper reinforcement layer comprised of molded plastic sheet and having an upper reinforcement pattern of opposingly-defined cavities and protrusions;
• wherein the upper reinforcement layer is affixed to the upper face with the upper reinforcement pattern being aligned with the core pattern.

A process for manufacturing a multi-layer composite pulp product, the process comprising:

• obtaining a first plastic sheet and a second plastic sheet, the first and second plastic sheets being comprised of a recycled plastic;
• fabricating a lower reinforcement layer from the first plastic sheet, the lower reinforcement layer having a lower reinforcement pattern of opposingly-defined cavities and protrusions;
• fabricating an upper reinforcement layer from the second plastic sheet, the upper reinforcement layer having an upper reinforcement pattern of opposingly-defined cavities and protrusions;
• forming a pulp layer having a core pattern of opposingly-defined cavities and protrusions;
• positioning the pulp layer on the lower reinforcement layer;
• placing the upper reinforcement layer on the pulp layer;
• and
• pressing the upper reinforcement layer, the pulp layer and the lower reinforcement layer together with the lower and upper reinforcement patterns being aligned with the core pattern;
• wherein the step of pressing is at a first selected heating temperature and under a first selected pressure.