Abstract: A method for forming a product from cellulosic material and thermoactive material is described. A mat is formed from a mixture having a predetermined amount of cellulosic material and a predetermined amount of thermoplastic material. The mat is then consolidated and pressed to a predetermined final product thickness. At least a portion of a surface of the mat or product is then surface modified. Consolidating the mixture may include forming a first face layer, forming a core layer on the first face layer, and forming a second face layer on the core layer. Forming the core layer may include depositing mixtures of wood flakes and plastic flakes according to mixture flake size in successive layers such that the core layer has larger flakes adjacent the first face layer and adjacent the second face layer, and smaller flakes in a middle portion of the core layer. The method also can include fusing a sheet of plastic material to at least one surface of the mat, and surface modifying the plastic material.

Abstract: A method for forming a product from cellulosic material and thermoactive material is described. A mat is formed from a mixture having cellulosic material and thermoplastic material. The mat is consolidated and pressed to a final thickness. At least a portion of a surface of the mat or product may be surface modified. Consolidating the mixture may include forming a first face layer, forming a core layer on the first face layer, and forming a second face layer on the core layer. Forming the core layer may include depositing mixtures of wood flakes and plastic flakes according to mixture flake size in successive layers such that the core layer has larger flakes adjacent the first face layer and adjacent the second face layer, and smaller flakes in a middle portion of the core layer. Consolidation can occur as a mat or composite moves through a hot-gas consolidation zone.