A self-supporting composite body comprising a substrate of discrete particles and a network of interconnected mycelia cells extending through and around the discrete particles and bonding the discrete particles together is characterized in being stiff and in having a density of greater than 18 pounds per cubic foot (pcf). The method of making the composite body includes compressing a mass of biocomposite material comprised of discrete particles and a network of interconnected mycelia cells in the presence of moisture into a compressed body having a density in excess of 18 pcf. Compression may take place batch wise in a press or continuously between a pair of movable endless conveyors.

A modular press suitable for use in the manufacture of EWC products may include a plurality of frame modules coupled together and aligned along a feed path axis. Each frame module may have a generally planar body supported on a corresponding pair of bases, an elongate aperture, an upper and a lower platform within the aperture, and a platen between the platforms. Optionally, the ends of the aperture may be curved. A first actuator system may be operable to move the platen from a raised position to an intermediate position, and a second actuator system may be operable to press the platen downwardly from the intermediate position onto a workpiece within the aperture. Some modular presses may include conveyor rolls and a third actuator system to raise and lower the conveyor rolls. In some embodiments, the actuator systems may be pneumatic actuator systems. Corresponding methods and systems are also described herein.

A modular press suitable for use in the manufacture of EWC products may include a plurality of frame modules coupled together and aligned along a feed path axis. Each frame module may have a generally planar body supported on a corresponding pair of bases, an elongate aperture, an upper and a lower platform within the aperture, and a platen between the platforms. Optionally, the ends of the aperture may be curved. A first actuator system may be operable to move the platen from a raised position to an intermediate position, and a second actuator system may be operable to press the platen downwardly from the intermediate position onto a workpiece within the aperture. Some modular presses may include conveyor rolls and a third actuator system to raise and lower the conveyor rolls. In some embodiments, the actuator systems may be pneumatic actuator systems. Corresponding methods and systems are also described herein.

Molded articles are provided. An exemplary molded article includes an inner panel portion, a main body portion, and a contoured portion extending between and interconnecting the inner panel portion and the main body portion so as to surround the inner panel portion and be surrounded by the main body portion. The contoured portion includes an outer angular region extending from the main body portion, an inner angular region extending from the inner panel portion, and a vertex region interconnecting the outer angular region and the inner angular region. The outer angular region includes contoured corner segments and contoured intermediate segments extending lengthwise between respective pairs of the contoured corner segments. The contoured intermediate segments have a first maximum thickness. The contoured corner segments have a second maximum thickness. The first maximum thickness is greater than the second maximum thickness. Related methods, assemblies, and apparatus are also provided.

Molded articles are provided. An exemplary molded article includes an inner panel portion, a main body portion, and a contoured portion extending between and interconnecting the inner panel portion and the main body portion so as to surround the inner panel portion and be surrounded by the main body portion. The contoured portion includes an outer angular region extending from the main body portion, an inner angular region extending from the inner panel portion, and a vertex region interconnecting the outer angular region and the inner angular region. The outer angular region includes contoured corner segments and contoured intermediate segments extending lengthwise between respective pairs of the contoured corner segments. The contoured intermediate segments have a first maximum thickness. The contoured corner segments have a second maximum thickness. The first maximum thickness is greater than the second maximum thickness. Related methods, assemblies, and apparatus are also provided.

A building panel including a multi-layered substrate having a back side layer with lignocellulosic particles and a binder, an intermediate layer with lignocellulosic particles and a binder, arranged on the back side layer, and a front side layer with lignocellulosic particles and a binder, arranged on the intermediate layer. The building panel further includes a front side wood veneer element attached to the front side layer of the multi-layered substrate, and a balancing element attached to the back side layer of the multi-layered substrate. The back side layer was formed from a first mixture, the intermediate layer was formed from a second mixture and the front side layer was formed from a third mixture where lignocellulosic particles from the second mixture and lignocellulosic particles from the third mixture are mixed, at least in a border area between the intermediate layer and the front side layer.

A building panel, such as a floor panel, or wall panel, having a multi-layered substrate including a back side layer comprising lignocellulosic particles and a binder, an intermediate layer including lignocellulosic particles and a binder which is arranged on the back side layer, and a front side layer including lignocellulosic particles and a binder, and which is arranged on the intermediate layer. The back side layer was formed from a first mixture, the intermediate layer was formed from a second mixture and the front side layer was formed from a third mixture. The building panel further has a mechanical locking device arranged along at least one edge portion of the building panel where the mechanical locking device is configured for horizontal and/or vertical locking of similar or essentially identical building panels in an assembled position.

A modular press suitable for use in the manufacture of EWC products may include a plurality of frame modules coupled together and aligned along a feed path axis. Each frame module may have a generally planar body supported on a corresponding pair of bases, an elongate aperture, an upper and a lower platform within the aperture, and a platen between the platforms. Optionally, the ends of the aperture may be curved. A first actuator system may be operable to move the platen from a raised position to an intermediate position, and a second actuator system may be operable to press the platen downwardly from the intermediate position onto a workpiece within the aperture. Some modular presses may include conveyor rolls and a third actuator system to raise and lower the conveyor rolls. In some embodiments, the actuator systems may be pneumatic actuator systems. Corresponding methods and systems are also described herein.

A modular press suitable for use in the manufacture of EWC products may include a plurality of frame modules coupled together and aligned along a feed path axis. Each frame module may have a generally planar body supported on a corresponding pair of bases, an elongate aperture, an upper and a lower platform within the aperture, and a platen between the platforms. Optionally, the ends of the aperture may be curved. A first actuator system may be operable to move the platen from a raised position to an intermediate position, and a second actuator system may be operable to press the platen downwardly from the intermediate position onto a workpiece within the aperture. Some modular presses may include conveyor rolls and a third actuator system to raise and lower the conveyor rolls. In some embodiments, the actuator systems may be pneumatic actuator systems. Corresponding methods and systems are also described herein.

A disclosed press 100 may flatten halved bamboo stalks or other workpieces without loss of volume or splintering. In a first mechanical movement executed by a pushrod drive train 300, a plurality of spreader bar assemblies 370 press upon the centerline of a workpiece such that the workpiece does not move off of a work surface but is yet not over crushed. Each spreader bar assembly may comprise two spreader bars 350 hingedly attached to a pushrod 345. The lower end of the pushrod and proximal ends 363 of the spreader bars pin down the workpiece. In a second mechanical movement executed by a crusher bar drive train 400, the distal ends of the spreader bars are moved outwardly and spread apart the curved walls of the workpiece. In the last phases of a second movement, planar track plates 440 press downwardly upon the workpiece.