An improved engineered wood product, and related methods, with improved actual and apparent surface quality. The product includes a high basis weight fines layer overlaying a strand matrix base layer, with one or more overlay layers. The fines layer may be placed between the overlay layers, if multiple overlays are present. The configuration of fines layer and overlay layer(s) minimizes the presence of sub-surface imperfections that may result in visible telegraphing on the exposed surface. A light pattern or texture may be embossed on the outermost overlay layer during the pressing process. Additionally, a paint primer layer or coating with added aggregate may be applied to help camouflage inherent sub-surface defects.

The general inventive concepts relate to engineered wood products. The engineered wood products demonstrate improved properties including acoustic damping, fire resistance, and water absorption relative to similar engineered wood products that comprise only a single source of fibers. In contrast, the inventive engineered wood products include a combination of at least two types of fibers.

A temperature-curable aminoplastic adhesive resin that is a (poly)-condensate of: (i) at least one aminoplast-forming chemical; (ii) 5-hydroxymethylfurfural (5-HMF), its oligomers and/or its isomers; and, (iii) at the least one second (poly-)condensable chemical produced in the presence of an organic sulfonic acid. Composite boards, such as wood-based panels, can be produced using this adhesive resin. The production of the aminoplastic adhesive resins includes the reaction of urea with 5-hydroxymethylfurfural (5-HMF) and glyoxal in the presence of an organic sulfonic acid as a hardener. The adhesive resin can be used in the production of wood-based panels, such as, particleboards, chipboards, fiberboards and products usually called, among others, plywood and/or blockboards, in the presence of an organic sulfonic during curing.

A press apparatus for vehicle crash pads including real wood sheets. The press apparatus includes a lower press including an engraved part, and a support part to support an upper press, the support part having a fixing protrusion, the upper press including an embossed part, first slides fixed to maintain a shape of the engraved part during a compression process of the real wood sheet, the first slides compressing a rear surface of the real wood sheet while rising along the embossed part, and a second slide to compress the real wood sheet during the compression process of the real wood sheet. During a wrapping process of the real wood sheet, the second slide compresses the real wood sheet to an inner rear surface of a core while falling such that a portion of the real wood sheet bent inward of the engraved part is wound around the core.

A press apparatus for vehicle crash pads including real wood sheets. The press apparatus includes a lower press including an engraved part, and a support part to support an upper press, the support part having a fixing protrusion, the upper press including an embossed part, first slides fixed to maintain a shape of the engraved part during a compression process of the real wood sheet, the first slides compressing a rear surface of the real wood sheet while rising along the embossed part, and a second slide to compress the real wood sheet during the compression process of the real wood sheet. During a wrapping process of the real wood sheet, the second slide compresses the real wood sheet to an inner rear surface of a core while falling such that a portion of the real wood sheet bent inward of the engraved part is wound around the core.

A hemp-based wood panel, and accompanying process. The hemp-based wood panels extend along mutually orthogonal x and y axes, and have a thickness along a z-axis orthogonal to the x and y axes. The panels comprise hemp shives and hemp fibers and a binder for joining the hemp stalks into a solid form. The processed hemp stalks are oriented along their length substantially at least quasi-isotropically, and optionally isotropically, wherein the processed hemp stalks extend isotropically oriented in the plane defined by the x-axis and y-axis, and extend anisotropically oriented in the plane defined by the y-axis and z-axis. Also, the processed hemp stalks constitute a weight percentage of at least 70% of the panel, and wherein the binder constitutes a weight percentage of at least 5% of the panel and at most 20% of the panel.

A method of producing a moulded article comprising a thermoset polymer and particles of porous natural materials, such as wood materials, and uses thereof. The composite material has a continuous matrix of a hardened thermoset polymer and, distributed within the matrix, and the particles are at least partially encased by the thermoset polymer. The method comprises the steps of providing a mould with two opposite pressing surfaces, said pressing surfaces defining a space between them; feeding particles of porous natural materials into the space between the pressing surfaces; advancing the surfaces towards each other to compress the particles in said space; feeding unhardened thermoset resin in liquid form into the mould so as to fill at least said space between pressing surfaces while keeping the particles compressed between the pressing surfaces; and curing the thermoset resin in the mould to provide a moulded composite article.

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 contoured corner segments and contoured elongated segments extending between respective pairs of the contoured corner segments. The contoured corner segments have a first maximum thickness. The contoured elongated segments have a second maximum thickness that is greater than the first 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 contoured corner segments and contoured elongated segments extending between respective pairs of the contoured corner segments. The contoured corner segments have a first maximum thickness. The contoured elongated segments have a second maximum thickness that is greater than the first maximum thickness. Related methods, assemblies, and apparatus are also provided.

A reverse molded, plant-on decorative panel component comprises a panel portion lying on a first plane, a skirt portion, and a contoured portion. The skirt portion has a first surface adapted to be exteriorly disposed and an opposite second surface adapted to be interiorly disposed in order to be adhesively secured to a planar surface. The contoured portion extends outwardly from and surrounds the panel portion and interconnects and is integral with the panel portion and the skirt portion. The skirt portion extends peripherally about the contoured portion.