Formation of a Structural Core Material from Recycled Fiber

Prior attempts to develop and commercialize a lightweight fiberboard panel have faltered due to lack of an industrially robust manufacturing process or significant limitations in end use performance properties. In this Proposed Phase I project, two continuous forming methods will be researched for producing a three-dimensional structural core material with properties suitable for widespread applications. Said core will be incorporated into a composite sandwich panel whose properties will be characterized by finite element analyses and ASTM test methods. Prototype decorative hardwood-veneered panels will be converted from core samples for preliminary commercial feasibility evaluation. A proposed path forward for Phase II research and development and early commercialization will be formulated following a critical analysis of the subject feasibility research.