Systems and methods of manufacturing engineered molded cellulose panels

Abstract

Building materials made of agricultural and other cellulosic byproducts and methods for their production. In production of these materials, cellulosic containing alloys are formed providing a slurry of the desired by-products, de-watered via a pressure press, optionally with several pressing and slurry application steps. The press optionally has desired properties, such as for acoustic engineering of the resulting panel. Resins are infused in the panels for desired water resistant or other properties.

What is claimed is: 
     
         1 . A wet process engineered molded cellulose composition comprising a pressed cellulose based board including a chopped agricultural cellulose embedded in a de-wetted matrix, infused with a resin. 
     
     
         2 . A process of manufacturing a cellulose based composition comprising:
 providing a first slurry containing at least one type of cellulosic fiber;   positioning the first slurry in a press having a specified profile;   de-watering the first slurry by exerting pressure within the press forming a shaped product;   removing the shaped product from the press; and   infusing the shaped product with a resin.   
     
     
         3 . The process of manufacturing a cellulose based composition of  claim 2  further comprising:
 providing a second slurry after de-watering; and 
 dewatering by exerting pressure within the press forming the shapes product including the de-watered first slurry and second slurry; 
 
     
     
         4 . The process of manufacturing a cellulose based composition of  claim 2  wherein the shaped product is a flat panel. 
     
     
         5 . The process of manufacturing a cellulose based composition of  claim 2  wherein the shaped product is a panel including at least one curve. 
     
     
         6 . The process of manufacturing a cellulose based composition of  claim 2  wherein the shaped product is a panel including an undulating surface. 
     
     
         7 . The process of manufacturing a cellulose based composition or  claim 2  wherein the first slurry includes fiber sources, preparations and alloys. 
     
     
         8 . The process of manufacturing a cellulose based composition or  claim 2  wherein the first slurry includes a fiber mix, with or without additives and with or without resin infusion. 
     
     
         9 . The process of manufacturing a cellulose based composition or  claim 2  wherein the first slurry includes a water resistant fiber mix, with or without additives, and with or without resin infusion. 
     
     
         10 . The process of manufacturing a cellulose based composition or  claim 2  wherein the first slurry includes a fire resistant engineered molded cellulose such as a fiber mix, with or without additives, with or without resins and coatings. 
     
     
         11 . The process of manufacturing a cellulose based composition or  claim 2  wherein the specific profile of the press includes a geometric pattern for desired acoustic properties of the product.