Post-press molding of man-made boards to produce contoured furniture parts

摘要

A method of molding a cellulosic fiber containing board at a temperature of at least 525 DEG F. to provide a relatively high density skin on at least one surface. A fibrous composition, including cellulosic fibers, is consolidated to form a blank having a density of less than 35 pounds/cubic foot. The blank is then cut to a shape larger in at least two of its three dimensions than corresponding dimensions of a mold cavity when said mold is in a closed position. Urea is then included in at least a surface layer of fibers of the blank in an amount of at least 5% based on the dry weight of the fibers contacted with urea, and thereafter the cut blank is molded to form a contoured product having a skin on at least one surface thereof, the skin defined by a thickness of material on said surface of said product having a density greater than the material on which the skin is formed.