Abstract: A process and assembly for producing a structural article, as well as an article produced according to any process and assembly. A mold has a base and a hinged lid, either or both of which include a cavity interior which defines a negative of the structural article to be produced. A structural insert placed within the mold, prior or subsequent to a plasticized and structural forming foam material also being placed within the mold. The foam cures and sets in encapsulating fashion around the insert so that, upon removal, the insert is coated within the formed material.

Abstract: An extruding process and assembly for creating a structural form, which includes the steps of bundling and conveying at least one length of a material into an extruder, reshaping a cross section of the bundle in a first stage of the extruder, extruding a material using any combination of heat and pressure around and between the lengths of material, and outputting a finished article having a cross sectional profile in which the materials are structurally supported by the extruded and hardened material. Other steps include an intermediate chilling stage between reshaping and extruding, and for preventing the extruded material from back flowing. The extruded material further includes any of a polymeric or structural foam material and can exhibit any of a rounded, square, rectangular or I beam cross sectional profile.

Abstract: An assembly and related process for producing a structural article from a naturally occurring organic material and which includes the steps of conveying a plurality of lengths of the naturally occurring material through a coating operation in order to apply a non-activated adhesive, following which the coated materials are transferred to a succeeding forming operation for shaping and solidifying into a reformed cross sectional shape suitable for a structural application. Additional steps include the naturally occurring organic material further including any of, burlap, bamboo, bamboo strips, cane stalks, corn stalks, palm leaves, and reeds. A catalyst ingredient is provided for coating the materials, the catalyst optionally being incorporated into the adhesive.

Abstract: The present invention discloses a line process for creating a multi-ply fiber sheet, which includes each of the steps of providing a non-activated adhesive fluid bath, immersing within the fluid bath a series of ply fiber sheets in order to coat a heat activated adhesive, stacking the sheets according to a desired plurality, and activating the adhesive within the stack to bond the sheets together. Other steps include pre cleaning and treating the sheets prior to immersing, as well as stacking individual ply fiber sheets in either of alternating lengthwise and crosswise seam extending fashion or in alternating and opposing diagonal extending fashion. The step of activating the adhesive can further include placing the stack into a heat press, as well as the use of any of liquid, light, steam, or heat.