Abstract: An improved apparatus for dry forming adhesive coated wood fibers in an airstream in a particular mold apparatus. The invention permits the manufacture of a mat of differing cross-sectional shapes but of uniform density. The invention includes the advantageous steps of final curing of the mat off of the main molding apparatus, thus achieving efficiencies in use.

Abstract: A sculptured structural fiberboard product is formed using a mold that includes porous forming areas which, in one embodiment, are porous forming mandrels movably mounted on the mold, and liquid impervious thimbles which removably cover the porous areas. A fiber network is formed as water is drained off through the porous areas and the thimbles are moved to gradually unveil the porous areas during the mat formation. When mandrels are used, the mandrels are withdrawn in cooperation with a pressing force applied to the mat to consolidate and dry the web. The porous areas can also act as heat and mass transfer means during consolidation and drying. An alternative embodiment permits formation of laminated products and another alternative embodiment permits close control over the product density during consolidation and drying.

Abstract: Apparatus and method for forming deckle-free edges and windows in molded fiber products such as cartons, trays and the like, said apparatus comprising a forming mold equipped with non-porous block-out ridge and/or patch members to define the periphery and/or windows in the finished product. The apparatus includes a mating press mold for cooperation with the forming mold with passageways therein through which jets of fluid such as air and/or steam may be supplied from a high pressure source to control deckle accumulated on the forming mold.