Method of molding powdered plant fiber into high density materials

A method of forming a high density plant fiber product comprising the steps of:

• (a) providing plant fibers containing protolignin and containing less than 20 per cent water by weight, the fibers being between 50 microns to 3000 microns in diameter;
• (b) blending a fluidized mixture of plant fibers and one or more of the group of additives consisting of a thermoset binding agent, a pigment, a releasing agent, a catalyst, a flame retardant, a flame resistant agent, a fire resistant agent, and a lubricating agent;
• (c) introducing the fluidized mixture of plant fibers and additives into the cavity of a mold;
• (d) compressing the mixture by applying a pressure of at least 500 psi to the surface of the mixture;
• (e) heating the contents of the mold cavity to between 50 degrees C. to 220 degrees C.;
• (f) curing the compressed contents;
• and
• (g) removing the compressed contents from the mold.

A method of manufacturing a high density plant fiber material comprising the steps of:

• (a) preparing a particulate mixture comprising plant fibers less than 1500 microns in diameter and containing protolignin, a thermoset binding agent, and one or more of the group of additives consisting of a pigment, a releasing agent, a catalyst, a flame retardant, a flame resistant agent, and a lubricating agent;
• (b) introducing the particulate mixture into a mold;
• (c) heating the particulate mixture to a temperature between 60 degrees C. and 220 degrees C.;
• (d) compressing the mixture to an average density of at least 60 pounds per cubic foot within the mold;
• and
• (e) removing the compressed contents from the mold.