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Method and apparatus for manufacturing fiber-reinforced, foamed paperlike products

  • US 6,521,147 B1
  • Filed: 12/02/1999
  • Issued: 02/18/2003
  • Est. Priority Date: 09/27/1996
  • Status: Expired due to Term
First Claim
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1. A method of manufacturing a molded product having a blown, foamy structure via an injection mold designed to form said molded product, said method comprising:

  • forming a fluid mass substantially free of gelatinized matter and having a low viscosity, said fluid mass comprising a natural polymer and natural fibers;

    maintaining said fluid mass at temperatures below a gelatinization temperature such that substantially no gelatinization of said natural polymers occurs in said fluid mass outside said injection mold;

    injecting said fluid mass under high pressure into said injection mold such that said fluid mass substantially fills said injection mold under said high pressure;

    heating said injection mold to raise the temperature of said fluid mass, while under said high pressure, to a baking temperature at least equal to or above said gelatinization temperature, to cause baking of said injected fluid mass with gelatinization and cross linking of said natural polymers, and with bonding of said natural polymers to said natural fibers to form said molded product with said natural fibers extending throughout said molded product; and

    removing said molded product from said injection mold.

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