MX2007007017A

MX2007007017A - Heat deflection/high strength panel compositions.

Info

Publication number: MX2007007017A
Application number: MX2007007017A
Authority: MX
Inventors: Garry E Balthes
Original assignee: Flexform Technologies Llc
Priority date: 2004-12-17
Filing date: 2005-12-16
Publication date: 2007-11-12
Also published as: WO2006065993A3; CA2590866A1; WO2006065993A2

Abstract

The following disclosure provides a structural mat for manufacturing a moldable structural hardboard body. The structural mat has a nucleated/coupled binder and a fibrous material. The nucleated/coupled binder material has a first binder material combined with a nucleating agent; and a second binder material combined with a coupling agent. The first binder material is combined with the nucleating agent to make a discrete nucleated/binder material. The second binder material is combined with the coupling agent to make a discrete coupled/binder material. The discrete nucleated/binder material and the discrete coupled/binder material are blended together. The fibrous material is blended with the discrete nucleated/binder material and the discrete coupled/binder material to form the structural mat.

Description

PANEL COMPOSITIONS WITH THERMAL DEFROST / HIGH RESISTANCE TECHNICAL FIELD This description relates to fiber mats, boards, panels, laminated compounds, uses and structures, and the process for making them. More particularly, a portion of the present disclosure relates to structural mats of high strength and high thermal deflection and resulting hard pasting panels. BACKGROUND AND BRIEF DESCRIPTION The industry is consistently moving away from members and structural panels of wood and metal, particularly in the vehicle manufacturing industry. Such members and structural panels of wood and metal have high resistance to weight ratios. In other words, the higher the resistance of the members and structural panels of wood and metal, the higher the weight. The resulting demand for members and structural panels of alternative material, thus, has risen proportionally. Due to their low resistance to weight ratios, as well as their resistance to corrosion, such non-metallic panels have become particularly useful as structural members in the vehicle manufacturing industry as well as the office structure industry, for example .

Frequently such non-metallic materials are in the form of composite structures or panels that are moldable into three-dimensional shapes for use in any variety of purposes. It would thus be beneficial to provide a composite structure having high strength using oriented and / or unoriented fibers with bonding agents having compatible chemistries to provide a strong bond through the layers of the composite. It would also be beneficial to provide a process of manufacturing and finishing coating for such structures in some modalities. It will be appreciated that the prior art includes many types of laminated composite panels and manufacturing processes therefor. U.S. Patent No. 4,539,253, filed March 30, 1984, entitled High Impact Strength Fiber Resin Ma trix Compositions, U.S. Patent Number 5,141,804, filed May 22, 1990, entitled Interleaf Layer Fiber Reinforced Resin Laminates Compositions, U.S. Patent No. 6,180,206 Bl, filed September 14, 1998, entitled Composition of Honeycomb Sandwi ch Panel for Fixed Leading Edges, U.S. Patent 5,708,925, filed May 10, 1996, entitled Mul ti -Layered Panel Having a Core Including Na tural Fibers and Method of Producing the Same, North American patent 4,353,947, filed on October 5, 1981, Lamina ted Composite Te Structure and Method of Manufacture US Pat. No. 5,258,087, filed on March 13, 1992, entitled Method of Making a Composition Structure, US Pat. No. 5,503,903, filed September 16, 1993, entitled Automotive Headliner Panel and Method of Making Same, U.S. Patent 5,141,583, filed November 14, 1991, entitled Method of and Appara tus for Continuously Fabrica ting Lamina te, U.S. Patent 4,466,847, filed May 6, 1983, entitled Method for the Continuous Production of Laminates, And U.S. Patent 5,486,256, filed May 17, 1994, entitled Method of Making to Headliner and the Like, are all incorporated herein by reference to establish the nature and characteristics of such laminated composite panels and manufacturing processes herein. It would be beneficial to provide a structural board that has fire retardant properties, as well as provide methods for making the panel. A portion of the following description relates to high strength, high thermal deflection panels. Illustratively, random or woven fibers can be joined and formed into a panel or mat using a combination of nucleated and coupled polypropylene. The nucleating agent can provide increased thermal deflection and the coupling agent can provide High resistance to the fiber panel. Other embodiments of the present disclosure may include a fiber panel comprising natural and / or synthetic fibers linked or bonded together using nucleated polypropylene. An alternative embodiment includes a natural and / or synthetic fiber panel comprising a coupling agent and polypropylene for joining the fibers together. The following description also provides a structural mat for the manufacture of a structural moldable structural board panel. The structural mat comprises a nucleated and / or coupled binder and a fibrous material. The nucleated / coupled binder material comprises: a first binder material combined with a nucleating agent; and a second binder material combined with a coupling agent. The first binder material is combined with the nucleating agent to make a discrete nucleate / binder material. The second binder material is combined with the coupling agent to make a discrete coupled material / binder. The discrete nucleate / binder material and the discrete coupled / binder material are mixed together. The fibrous material is mixed with the discrete nucleate / binder material and the discrete coupled material / binder to form the structural mat.

In the foregoing and other illustrative embodiments, the structural mat may further comprise: the first and the second binder materials each being polypropylene; both the discrete nucleate / binder material and the discrete coupled / binder material are in fibrous form; the first binder material combined with the nucleating agent further comprises about 4% nucleating agent with the remainder being the first binder material; the second binder material combined with the coupling agent further comprises about 5% coupling agent with the remainder being the first binder material; the mat comprises approximately 25% discrete nucleate / binder material; the mat comprises approximately 25% discrete coupled material / binder; the mat comprises approximately 50% of the fibrous material; the mat comprises about 25% discrete nucleate / binder material with about 2% of the structural mat which is the nucleating agent, about 25% discrete coupled material / binder with about 2.5% of the structural mat which is the coupling, and approximately 50% fibrous material; the nucleating agent which is an aluminosilicate glass; the coupling agent which is maleic anhydride; the discrete nucleate / binder material and the discrete binder / binder material are mixed homogeneously; the fibrous material which is a randomly oriented fibrous material; a randomly oriented fibrous material that is a natural fiber material; and the fibrous material that is a woven material. Another illustrative embodiment of the present disclosure provides a structural panel having high strength and high thermal deflection properties. The panel comprises a rigid body comprised of solidified nucleated / coupled binder material and fibrous material. Both materials are dispersed throughout the thickness of the body. The solidified nucleated / coupled binder is formulated from a material nucleated by a binder and a material coupled with a binder. In the foregoing and other illustrative embodiments, the structural panel may further comprise: the nucleated / coupled binder material comprising polypropylene; about 50% of the nucleated / coupled polypropylene comprising about 4% nucleating agent and about 5% coupling agent, and about 50% fibrous material; the nucleating agent which is an aluminosilicate glass; the coupling agent which is maleic anhydride; the fibrous material which is a randomly oriented fibrous material; the randomly oriented fibrous material that is a material of natural fiber; the fibrous material is a woven material; the nucleated / coupled polypropylene which is in a concentration of about 40% to 50%; the fibrous material that is in a concentration of approximately 50% to 60%. Another illustrative embodiment of the present disclosure provides a method for making a structural mat for the manufacture of a structural moldable structural board panel. The method comprising the steps of: combining a nucleating agent with a first polypropylene material; forming a solid fibrous combination of nucleating agent and the first polypropylene material; combining a coupling agent with a second polypropylene material, separated from the mixed nucleating agent and the first polypropylene material; forming a solid fibrous combination of coupling agent and the second polypropylene material; mixing the solid fibrous combination of nucleating agent and the first polypropylene material with the solid fibrous combination of coupling agent and the second polypropylene material; mixing a fiber material with the mixed solid fibrous combination of the nucleating agent and the first polypropylene material and the solid fibrous combination of the coupling agent and the second polypropylene material; and form a structural mat by combining the fiber material with the mixed solid fibrous combination of the nucleating agent and the first polypropylene material and the solid fibrous combination of coupling agent and the second polypropylene material. In the foregoing and other illustrative embodiments, the method may further comprise the steps of: formulating the nucleating agent and the first polypropylene material with about 4% nucleating agent and the remainder being the first polypropylene material; formulating the coupling agent and the second polypropylene material with about 5% of the coupling agent and the remainder being the second polypropylene material; provide about 25% nucleating agent and the first polypropylene material; provide about 25% coupling agent and the second polypropylene material; provide approximately 50% fibrous material; provide about 25% nucleating agent and the first polypropylene material with about 2% of the structural mat which is the nucleating agent, about 25% of coupling agent and the second polypropylene material with about 2.5% of the structural mat which is the coupling agent, and about 50% fibrous material; mix the nucleating agent and the first polypropylene material and the agent coupling and the second polypropylene material homogeneously; providing the nucleating agent and the first polypropylene material and the coupling agent and the second polypropylene material in a concentration of about 40% to 50%; provide the fibrous material in a concentration of about 50% to 60%; heating the structural mat to at least the melting temperature of the first and second polypropylene material; set the pressure to the structural mat; and forming a pressed board body from the mat. Additional features and advantages of this description will become apparent to those skilled in the art in consideration of the following detailed description of the illustrated modes exemplifying the best mode of carrying out such modalities as they are currently perceived. BRIEF DESCRIPTION OF THE DRAWINGS The present description will be described hereinafter with reference to the accompanying drawings which are given as non-limiting examples only, in which: Fig. 1 is a schematic side view of a laminated pressed board panel; Fig. 2 is a side view of the laminated pressed table panel of Fig. 1 in a formed configuration illustrative; Fig. 3 is a perspective view of a portion of the laminated pressed table panel of Fig. 1 showing plies partially peeled off layers of nonwoven material; Fig. 4 is another embodiment of a laminated pressed table panel; Fig. 5 is another embodiment of a laminated pressed table panel; Fig. 6 is another embodiment of a laminated pressed table panel; Fig. 7 is a perspective view of a honeycomb core laminate panel; Fig. 8 is a schematic, top view of the honeycomb section of the panel of Fig. 7; Fig. 9 is a perspective view of a portion of the honeycomb section of the panel of Fig. 7; Fig. 10 is a perspective view of a lattice core laminated panel; FIG. 1 is a side view of an illustrative hinged visor body in the open position; Fig. 11b is a detailed view of the articulation portion of the visor body of Fig. 1a; Fig. 12a is a side view of an illustrative hinged visor body in the folded position; Fig. 12b is a detail view of the hinge portion of the visor body of Fig. 12a; Fig. 13 is a final view of a mold assembly for compression molding a body of fiber material and a joint; Fig. 14a is a top view of the visor body of Figs. 11 and 12 in the open position; Fig. 14b is an illustrative visor fastening bar; Fig. 15 is a perspective view of a wall panel comprising a laminated panel body; Fig. 16 is a work body; Fig. 17 is a sectional end view of a portion of the working body of Fig. 16 showing an illustrative connection between the first and second portions, Fig. 18 is a sectional end view of a portion of the working body of Fig. 16 showing another illustrative connection between the first and second portions; Fig. 19 is a sectional end view of a portion of the work body of Fig. 16 showing another illustrative connection between the first and second portions; Fig. 20 is a side view of a pressed table manufacturing line; Fig. 21a is a top view of the pressed table manufacturing line of Fig. 20; Fig. 22 is a side view of the unwinding and coupling steps of the manufacturing line of the pressed board of Fig. 20; Fig. 23 is a side view of the preheating stage of the manufacturing line of the pressed board of Fig. 20; Fig. 24 is a side view of the steps of heating, pressing and cooling the manufacturing line of the pressed board of Fig. 20; Fig. 25 is a side view of a rolling station and shearing and cutting steps as well as a finishing step of the manufacturing line of the pressed board of Fig. 20; Fig. 26 is a top view of the rolling station and the shearing and cutting steps as well as the finishing step of the manufacturing line of the pressed board of Fig. 20; Fig. 27 is a side view of a portion of the step of this rolling station of the manufacturing line of the pressed board of Fig. 20; Fig. 28 is another top view of the shearing and trimming steps as well as the finishing step of the manufacturing line of the pressed board of Fig. 20; Fig. 29 is a top view of another embodiment of a laminated pressed table manufacturing line; Fig. 30 is a side view of the calendering step of the manufacturing line of the pressed board of Fig. 29; Fig. 31 is a diagrammatic and side view of a portion of a material recycling system; Fig. 32 is a side view of a material recycling system and a manufacturing line of the laminated pressed board; Fig. 33 is a top view of the material recycling system and the manufacturing line of the laminated pressboard of Figs. 31 and 32; Fig. 34 is a diagram of mechanical properties comparing the tensile and flexural strength of an illustrative laminated pressed table panel with industrial standards; Fig. 35 is a diagram of mechanical properties comparing the flexural modulus of an illustrative laminated pressed table panel with industrial standards; Figs. 36a to c are sectional views of the layer of fibrous material subjected to various amounts of heat and pressure; and Fig. 37 is a diagram showing an illustrative manufacturing process for a fire retardant structural board. The corresponding reference characters they indicate corresponding parts for all the various views. The exemplification set forth herein illustrates various embodiments, and such exemplification will not be construed as limiting the scope of the description in any way. DETAILED DESCRIPTION OF THE DRAWINGS A schematic side view of a laminated composite pressed board panel 2 is shown in Fig. 1. The pressed board panel 2 illustratively comprises a fascia cover material 4 positioned as the surface layer of the panel 2 The fascia cover material 4 can be comprised of fabric, vinyl, leather, acrylic, epoxy, or polymer, etc. It is appreciated, however, that the pressed table panel 2 may or may not include such fascia cover. The laminated composite pressboard panel 2 illustratively comprises a first layer sheet of fibrous material 6. The layer of fibrous material 6 illustratively comprises a natural fiber, illustratively about 25 percent by weight of hemp and about 25 percent by weight of kenaf with the rest which is illustratively polypropylene. The fibers are randomly oriented to provide a non-specific resistance orientation. Variations of this fibrous material are contemed including the combination of about 24.75 weight percent hemp and about 24.75 weight percent kenaf with about 50 weight percent polypropylene and about 0.05 weight percent maleic anhydride. Other such fibrous materials can also be used, such as flax and jute. It is also contemed that other mixing ratios of the fibrous material can be used to provide a non-specific orientation of strength. It is further contemed that other binders in e of polypropylene may also be used for the purpose discussed hereinafter. In addition, it is contemed that other fibrous materials having high process temperatures above about 204 degrees C (400 degrees F), for example, may also be used. A layer of woven fiber 8 illustratively comprises a glass woven with a polypropylene binder, and is illustratively located between the layers of fibrous material 6. It is appreciated that other such non-metallic fiber materials may be used in e of glass, including Nylon, Kevlar, fleece and other natural or synthetic fibers. Such woven fiber provides bidirectional strength. In contrast, the layers of fibrous material 6 provide non-specific directional resistance, thus giving the composite increased multidirectional resistance. Each surface 10 of the layers of fibrous material 6 that are adjacent to the layer of woven material 8 are joined to the surface 12 of the layer 8. A bond is created between the layer of fibrous material 6 and the layer of woven material 8 by a process of melting high temperature and pressure as discussed later in the present. Because the glass and fibrous layers have compatible binders (ie, polypropylene, or comparable binder), the layers 6, 8 will melt and bond, forming an amalgamated bond therebetween. The layers 6, 8 having polypropylene as a common chain in each of their respective chemistries make the layers compatible and treatable for three-dimensional molding, for example. It is appreciated that the panel 2 may comprise a plurality of layers of fibrous material 6, with layers of woven material 8 laminated between each pair of adjacent surfaces 10 and 12, respectively. A detached view of the pressed table panel 2, shown in FIG. 3 illustrates such combined use of non-specific or randomly oriented directional fibers. The random fibers 14 constitute the layer of fibrous material 6, while the woven fibers 16 constitute the layer of fiber 8. Because the mass in volume can increase the strength of the panel, it is contemed that more fibrous and woven fiber layers Alternating materials used in the laminate compound will increase the strength of the panel. The number of layers used, and which layer (s) will be the outer layer (s), can be varied and is often dictated by the requirements of the particular application. The test was conducted on illustrative pressboard panels to demonstrate tensile and flexural strength. The pressed board laminate consisted of a first layer of 80 percent polypropylene, 20 percent polyester fleece of 600 grams, a second layer of glass fiber blend of 650 grams (75 percent glass of .75 K / 25 percent polypropylene and 10 percent maleic anhydride), a third layer of 25 percent hemp / 25 percent kenaf of 1800 grams with 5 percent maleic anhydride and the remainder polypropylene, a fourth layer of fiberglass blend of 650 g, and a fifth layer of 20 percent polyester fleece, 80 percent polypropylene of 600 g. This resulted in a pressed board panel of 4300 grams of total weight. The final panel was formed by subjecting it to 200 degrees C (392 degrees F) with a 6-millimeter opening and heating for approximately 400 seconds. The material was then pressed using a 4.0 millimeter aperture. The final composite panel resulted in an approximate final thickness of 4.30 mm. To determine such tensile and flexural properties of the panel, ASTM 638-00 and ASTMD 790-00 were used as guides. The shape and size of the panel samples conformed to the specification outlined in the standards as close as possible but that the thickness of the sample varied slightly as noted above. A Tinius Olson Universal test machine that uses specific industrial attachments was used to carry out the tests. Two lauan boards were coated with a gel coating finish and formed into tables of thickness of 2.7 millimeters and final 35 millimeters, respectively. These tables were used as a baseline for comparison with the pressed table panel of the present disclosure. Each of the samples was then cut to the shape and sizes according to the previous standards. The tensile and flexural properties of the boards of the lauan were determined in the same way as the previous pressed table panel. Once the results were obtained then they were plotted against the results of the pressed table panel for comparison, as shown below and in Figs. 34 and 35. The results herein represent in averages over 10 samples tested from each table.

As represented by Fig. 2, the laminated panel 2 can be formed into any desired shape by methods known to those skilled in the art. It is appreciated that the three-dimensional molding characteristics of various fibrous sheets in combination with the structural support and the strength characteristics of the woven glass / polypropylene materials located between pairs of the fibrous sheets will produce a laminated composite that is highly three-dimensionally moldable while maintains high tensile and flexural resistances. Such a laminated panel is useful for the molding of structural wall panel systems, structural automotive parts, side wall panels highway trailers (exterior and interior), sidewall panels of recreational vehicles (exterior and interior), automotive cargo floors and building construction, roof systems, modular built-up wall systems, and other such moldable parts. Such a panel can replace chemical hardened polymers based on styrene, metal, sawn timber, tree cut, and other similar materials. It is believed that such a moldable laminated panel can reduce part of the cost, improve air quality with the reduced use of styrene, and reduce part of the weight. Such a panel can also be recyclable, thus giving the material a sustainability presence. Another embodiment of a pressed board panel 20 is shown in Fig. 4. This panel 20 comprises a layer of fibrous material 6 that serves as the core, and is joined by the layers of glass fiber 22 and the layers of fleece 24 , as shown. For example, the layer of fibrous material 6 may comprise the conventional unoriented fiber / polypropylene blend as discussed previously, illustratively weights of 1800 or 2400 g. the fiberglass layer comprises a mixture of 50 weight percent polypropylene / 50 weight percent maleic polypropylene (illustratively 400 g / m2). The fleece layer comprises a blend of approximately 50 weight percent polypropylene and about 50 weight percent polyester (illustratively 300 g / m2). The fleece material provides good adhesion with polypropylene and is waterproof under ambient conditions. In addition, polyester is a pair compatible with polypropylene because it has a higher melting temperature than in polypropylene. This means that the polypropylene can be melted and bonded to the other layer without adversely affecting the polyester. In addition, maleic anhydride is an effective hardening people that has high tensile and flexural strength which increases the panel's full strength. It is contemplated that the scope of the invention herein is not limited solely to the amounts, weights and ratio mixtures mentioned in the foregoing of the material and the binder. For example, the fleece layer 24 may comprise a blend of about 80 weight polypropylene / polyester at about 20 weight percent (illustratively 600 g / m2). The laminated composite panel 20 shown in Fig. 4 may include, for example, both fleece layers 24 comprising the 50/50 polypropylene / polyester blend, or a layer 24 comprising the 50/50 polypropylene / polyester blend, or the 80/20 polypropylene / polyester blend. In addition, the same as panel 2 the binder used for panel 20 can be any suitable binder such as polypropylene, for example.

Another embodiment of a laminated pressed table panel 28 is shown in Fig. 5. This panel 28 comprises a layer of fibrous material 6 which serves as the core which is joined by the layers of fleece 24, as shown. As with the panel 20, the fibrous material layer 6 of the panel 28 may comprise the unoriented fiber / polypropylene blend, conventional as previously discussed in illustrative weights of 1800 or 2400 g. Each layer of fleece 24 may comprise a blend of about 50 weight percent polypropylene / about 50 weight percent polyester (illustratively 300 g / m 2). Or it may alternatively be a polypropylene blend of about 80 weight percent / polyester at about 20 weight percent (illustratively 600 g / m2). 0, still alternatively, a fleece layer 24 can be the 50/50 mixture and the fleece layer 24 can be the 80/20 blend, for example. Another embodiment of a laminated pressed table panel 30 is shown in Fig. 6. This panel 30 similar to the panel 20 shown in Fig. 4 comprises a layer of fibrous material 6 which serves as the core which is joined by the layers of fiberglass 22 and the layers of fleece 24. The formulations for and variations of the fleece layer 24, the glass fiber layers 22 and the layer of fibrous material 6 may comprise the formulations described in FIG. embodiment of panel 20 shown in Fig. 4. Laminated panel 30 further comprises a calendered surface 32, and illustratively, a top quality painted or coated surface. The calendering process assists in the manufacture of a Class A finish for automotive bodies. A Class A finish is a finish that can be put on the elements of the climate and still maintains its aesthetics and quality. For example, one embodiment of the coated surface 34 contemplated herein is designed to meet General Motors' engineering standard for exterior paint performance: GM4388M, rev. June 2001. The process for applying the coated finish 5 or coated is described with reference to the calendering process additionally in the present immediately. The additional illustrative embodiment of the present disclosure provides a moldable panel material, for use as a roof liner, for example, comprising the following weight percent constituents: about 10 weight percent of polypropylene fibers consisting of polypropylene (about 95 weight percent) coupled with maleic anhydride (about 5 weight percent), although it is contemplated that other couplers may also work; about 15 weight percent kenaf fiber (or similar fibers such as hemp, flax, jute, etc.) with an antifungal / antimicrobial agent containing about 2 weight percent active ingredient; wherein the fibers can be pre-treated off-line before mixing; about 45 weight percent bicomponent polyester (about 4 diners); wherein the bicomponent mixing ratio is about 22.5 weight percent high melting polyester (about 226 degrees C (440 degrees F)) and about 22.5 weight percent low melting polyester (about 115 degrees C) about 149 degrees C (about 240 degrees F) to about 300 degrees F which is slightly below the full melting temperature of the polypropylene to allow control of the movement of the polypropylene during the heating phase); wherein, alternatively, similar fibers of similar chemistry can also be used; and about 30 weight percent component polyester fiber alone (approximately 15 diners) high melting (approximately 226 degrees C (approximately 440 degrees F)); wherein alternatively, similar fibers of similar chemistry can be used. Again, such material can be used as a roof liner. This is because the formulation has a higher heat deflection created by stable fibers and high melt polypropylene, and by the polyester and polymer crosslinked to the polymer of these fibers. In addition, it has been crosslinked with the low melting non-compatible polyester to form a common melting combined polymer that demonstrates higher heat deflection intervals. Natural fiber treated antifungal protects any cellulose in the fiber from the colonization of mold for the life of product the roof lining must be exposed to high humidity conditions. It is appreciated that other formulations can work as well. For example, another illustrative embodiment may comprise about 40 percent bicomponent fiber with a melting temperature of 180 ° C, about 25 percent of the single PET-15 diners component; about 15 percent polypropylene G3015 and about 20 percent fine grade natural fiber. Another illustrative embodiment may comprise about 45 percent bicomponent fiber semicrystalline melting temperature of 170 ° C, approximately 20 percent single component PET-15 diner, approximately 15 percent low melt flow polypropylene (10-12 mfi) and approximately 20 percent fine grade natural fiber . It is further contemplated that such compositions disclosed herein may define approximate limits of usable formulation ranges of each of the constituent materials. A cropped view of a panel composed of honeycomb 40 is shown in Fig. 7. The illustrated embodiment comprises the top and bottom panels, 42, 44 with a honeycomb core 46 located therebetween. An illustrative embodiment provides a polypropylene honeycomb core sandwiched between two panels made of a randomly oriented fibrous material. The fibrous material is illustratively about 30 weight percent fiber and about 70 weight percent polypropylene. The fibrous material is illustratively comprised of 50 percent kenaf and about 50 percent by weight hemp. It is contemplated, however, that any fiber similar to hemp, such as flax or other fiber based on cellulose, may be used in place of hemp or kenaf. In addition, such materials can be mixed in any other suitable mixing ratio to create such suitable panels. In an illustrative embodiment, each panel 42, 44 is compressed with heat in the honeycomb core 46. The higher polypropylene content used in the panels provides more thermal plastic available to create a fusion bond between the panels and the honeycomb core. . During the manufacture of such panels 40, the heat is applied to the interior surface 48, 50 of the panels 42, 44, respectively. The heat fuses the polypropylene on the surfaces which can then bind the polypropylene material that makes up the honeycomb core. It is appreciated, however, that other ratios of fiber to polypropylene to other bonding materials may be used, while a bond may be created between the panels and the core. In addition, other bonding materials, such as an adhesive, can be used in place of polypropylene for either the panels or the core, while the chemistries between the bonding materials between the panels and the core are compatible to create a enough union. A top detail view of an illustrative embodiment of the panel core 46 is shown in Fig. 8. This illustrative embodiment comprises individually bonded battens 52. Each batten 52 is formed in a shape similar to the illustrative battlement having alternating merlons. and battlements 56. Each of the corners 58, 60 of each merlon 54 is illustratively thermally bonded to each corresponding corner 62, 64 respectively, of each crenella 56. Such seams 66 illustratively running to the length of the corners are shown in Fig. 9. The successive rows of such laths formed and linked 52 will produce the honeycomb structure, as shown. Another embodiment of the honeycomb panel comprises a honeycomb core of fibrous material instead of the polypropylene honeycomb core. Illustratively, the honeycomb core of fibrous material may comprise about 70 weight percent polypropylene with about 30 weight percent fiber, for example, similar to that used for the upper and lower panels 42, 44, previously discussed, or even at a mixture of 50/50 weight percent. Such formulations are illustrative only, and other formulations that produce a high strength table are also contemplated herein. A perspective view of a lattice composite 70 is shown in Fig. 10. The lattice panel composite 70 is a high strength, lightweight panel for use in bi-or three-dimensional body panel applications. The illustrative embodiment of the lattice composite 70 comprises the upper and lower layers 72, 74 respectively, which interspersed the member core. lattice 76. Each of the layers 72, 74, 76 is made of a combination of fibrous / polypropylene material similar to that described in the above embodiments. Each layer 72, 74, 76 comprises a non-directional fibrous material, illustratively, about 25 weight percent hemp and about 25 weight percent kenaf with the remainder being polypropylene. The fibers were randomly orientalized to provide a non-specific orientation of strength. Illustrative variations of this fibrous material are contemplated, which may include, for example, a combination of about 24.75 weight percent hemp and 24.75 weight percent kenaf with 50 weight percent polypropylene and 0.05 weight percent of maleic anhydride. Other ratios of fibrous materials, however, are also contemplated to be within the scope of the invention. In addition, other fibrous materials by themselves are contemplated to be within the scope of the invention. Such materials can be flax, jute, or other similar fibers that can be mixed in various ratios, for example. Additionally, it is appreciated that other binders in place of polypropylene can be used to achieve the utility contemplated herein. The lattice core 76 is formed illustratively with a plurality of angled support portions 78, 80 for support and distribution of beneficial weight. In the illustrated embodiment, the support portion 78 is oriented at a surface angle relative to the upper and lower layers 63, 74, respectively, than the support portion 80 which is oriented at a steep angle. It is appreciated that such support portions can be formed by using a stamping die, continuous forming tool, and other similar method. It is further appreciated that the thickness of any of the layers 72, 64, or even in the lattice core 76 may be adjusted to accommodate any variety of loading requirements. In addition, the separation between the layers 72, 74 can also be increased or decreased to effect their load resistance. Between each support portion is an alternating contact portion, either 82, 84. The outer surface of each of the alternating contact portions 82, 84 is configured to link one of the inner surfaces 86, 88 of the layers 72, 64, respectively. To create the joint between the layers 72, 74 and the lattice core 76, the surface surface heat, approximately 232 degrees C (250 degrees F) for the polypropylene are applied to the contact surfaces to melt the surface layer of the polypropylene , similar to the process discussed later in the present. At this temperature, the polypropylene or other binder material is sufficiently mixed to bond it with the core polypropylene. In this illustrative embodiment, the contact portion 82 is attached to the surface 86 of the upper layer 72, and the contact portion 84 is attached to the surface 88 of the layer 74. Once solidified, a complete joint will be formed without the need for an additional adhesive. It is appreciated, however, that an adhesive can be used in place of the surface heat bond. The outer surfaces of the layers 72, 74 can be configured to accommodate a fascia cover material (not shown). Such fascia cover material can be compressed from fabric, vinyl, acrylic, leathers, epoxies, or polymers, paint, etc. In addition, the surfaces of layer 72, 74 can be treated with polyester to waterproof the panel. A final view of an articulated visor body 90 is shown in Fig. This description illustrates a visor, similar to a sun visor used in a car. It is appreciated, however, that such a visor body 90 is disclosed herein for illustrative purposes, and it is contemplated that the visor does not solely represent the application of a formed articulated body. It is contemplated that such is applicable to any other application that requires an appropriate articulated body. In the illustrative embodiment, the body 90 comprises body portions 92, 94 and an articulation 96 placed between them. (See Figs 11b and 12b). The body 90 is illustratively made of a low density fibrous material, as is further described herein below. In one embodiment, the fibrous material may comprise a randomly oriented fiber, illustratively of about 50% by weight of hemp or kenaf similar to fiber with about 50 weight percent of the polypropylene. The material is subjected to hot air and variable compression zones to produce the desired structure. (See additionally, Fig. 13). Another illustrative embodiment comprises about 25 weight percent hemp and about 25 weight percent kenaf for the remainder which is polypropylene. Approximately, all of the fibers are randomly oriented to provide a non-specific resistance orientation. Other variations that this composition contemplates include, but are not limited to, about 24.75 weight percent hemp and about 24.75 weight percent combination of kenaf with about 50 weight percent polypropylene and about 0.05 weight percent of maleic anhydride. Additionally, other fibrous materials are contemplated to be within the scope of this disclosure, such as flax and jute in various ratios, as well as fibers in various other mixing ratios. It is also appreciated that other binders instead of polypropylene they can also be used for the utility discussed here. The illustrative embodiment of the body 90 comprises the hinge portion 96 which allows the adjacent body portions 92, 94 to move relative to each other. The illustrative embodiment shown in Figs. lia and b represent the body 90 in the unfolded position. This embodiment comprises the body portions 92, 94 having a thickness such that the hinge portion 96 is provided adjacent the depressions 98, 100 on the portions of the surface body 92, 94, respectively. Because the body 90 is a unitary body, the flexibility of the articulation portion 96 is derived from the same formation in a relatively thin member, as discussed hereinafter. From such bending situations as shown in Fig. 12a, the material adjacent to the joint may interfere with the body's ability to completely bend. These depressions 98, 100 allow the body portions 92, 94 to bend as shown in Fig. 12a, without the material of the portions of the body interfering therewith. As shown in Fig. 12b, a cavity 102 is formed when the body portions 92, 94 are completely folded. It is contemplated, however, that such occasions may arise where it can not be desired to remove such a portion of articulation. adjacent material 96, as shown with depressions 98, 100. Such cases are contemplated to be within the scope of this disclosure. In the illustrative embodiment shown in Fig. 11b, the articulation portion 96 forms an arcuate path between the portions of the body 92, 94. The spokes assist in the removal of a slit that can occur in the joint when the joint is approximately 180 degrees. degrees of curvature. As shown in Fig. 12 b, the hinge portion 96 loses some of its arcuate shape when the body portions 92, 94 are in the bent position. It is appreciated, however, that such articulation 96 is not limited to the arcuate shape shown in FIG. Rather, the hinge portion 96 can be any shape while facilitating relative movement between the connection of the two body portions. For example, the hinge portion 96 may be linear in shape. The shape of the joint portion can also be influenced by the size and shape of the portions of the body, as well as the desired amount of movement between the body portions. Illustratively, in addition, or instead of, the fibrous material that forms the visor joint via the high pressure alone, the joint can also be formed by having a strip of material removed in the area of joint. In an illustrative embodiment, a joint having a width of about 1/8 inch wide and a removal depth of about 70 weight percent thick masses allows the full compression thickness of the joint after casting. approximately 0.03125 inches, for example. The convex molding of the joint can straighten it during the final bending assembly, providing a straight mid-line edge between the two final spokes. It is contemplated that the mold for the mirror depressions, etc., plus the additional surface molding details can be achieved using this process. It is further anticipated that the strong paper can be applied during the molding process where the cover is attached to the visor by the polypropylene contained in the fibrous material formulation. The illustrative embodiment of the body 90 includes longitudinally extending depressions 93, 95 which form a cavity 97. (See Figs., 12a and 14a). The cavity 97 is configured to receive the bar 99, as discussed hereinafter. (See Fig. 14b). It is appreciated that such depressions or cavities described herein with respect to the body 90 are for illustrative purposes. It is contemplated that any design that requires such a moldable body and articulation can be achieved consistent with the present description herein. As previously dssed, the body 90 can be comprised of low density material to allow for variable forming geometry in the visor structure. For example, high and low compression zones to allow pattern formation. For example, the panel portion may be a low compression zone, while the articulation portion is a high compression zone. In addition, the high compression zone may have material removed illustratively by a saw cut during production, if required, also as previously dssed. This allows a thinner high compression zone that facilitates the ability for the material to be flexed back and forth without fatigue, useful for such a joint portion. A final view of a mold assembly 110 for compression molding a body of fiber and articulation material is shown in Figure 13. The shape of the mold assembly 110 shown is in an illustrative manner. It is contemplated that such a body 90 can be formed in any desired shape. In the illustrated embodiment, the assembly 110 comprises illustrative press plates 112, 114. Illustratively, the molds 116, 118 are attached to the plates 112, 114, respectively. The mold 116 is formed to reflect the corresponding portion of body 90. It is appreciated that because the view of Figure 13 is a final view, the molds may extend longitudinally to any desired length. This illustrative embodiment of the mold lldincludes the surface 120, 122 and includes the compression zones 124, 126, 128, 130. The zones 124, 126 are illustratively protuberances that help form the depressions 93, 95, respectively, of the body 90, as it shows. (See also Fig. Ia.) Zone 128, 130 are illustratively protuberances that help form depressions 98,100, respectively, of body 90 as shown. (See also FIG. 1A.) And the zone 132 is illustratively a form which, in cooperation with the area 134 of the mole 118, forms the hinge portion 96. This illustrative embodiment of the mold 118 includes the surfaces 136, 138 and includes the compression zones 140, 142, 134. The zones 140, 142 are illustratively inclined walls that help form the zones 134. (See also Fig. 1a.) The zone 134 is illustratively a peak which, cooperatively in the zone 132 creates a high compression zone to form the hinge portion 96, and, illustratively, the depressions 98, 100 if desired. Again, it is appreciated that the present pattern of such areas shown is not the only such pattern contemplated by this description. In the illustrated embodiment, the body 90, in the illustrative form of an articulated visor, it is folded like that shown in Fig. 12a. It is further contemplated that during the formation of the body it can be heated by hot air to bring it up to forming temperatures. The heating cycle time can be about 32 seconds, and the charging time after the clamp to cool it will be around 45 to 50 seconds, depending on the temperature of the tool. In addition, skins, similar to cloth skin can be attached to the visor during this stage. Another embodiment of the pressed board panel is a low density panel, illustratively, a panel of approximately 2600 grams with approximately 50 weight percent hemp, fiber-like linen, or other fiber material with approximately 50 weight polypropylene. Such materials are subjected to hot air to produce a low density, lightweight panel. The panel material can be perforated with a needle or has a stretched thin layer surface applied thereon for use as a nailable panel with studs, wall boards, ceiling tiles, or similar structures to interior panels. A portion of a dry erase board is shown in Fig. 15. Such board 150 may comprise a pressed board panel 152 (similar to panel 2) according to the above description together with the coating of surface 154. The surface coating, such as that described hereinafter, provides an optimum work surface as a dry erase board. The surface coating 154, for example, may be a previously described Class A finish. This illustrative embodiment includes a portion of structure 156 to increase the aesthetics of table 150. One embodiment may comprise a dry erase table with a board for low density advertisements on one side and a pressed table of dry erase on the other side. An illustrative embodiment of a work body in the form of a table surface 180, is shown in Fig. 16. The view illustrated herein is a partial cut-away view showing the coupling of an upper part 180 to a lower part 184. An illustrative pedestal 186 supports the table surface 180 in a conventional manner. It is appreciated, however, that the table surface 180 is shown in an exaggerated view relative to the pedestal 186 to better illustrate the relevant detail of the surface table 180. In the illustrated embodiment, the periphery 188 of the top 182 is precisely formed to create a working surface edging the upper phase 182 is joined to the lower part 184 by way of a portion of the periphery 190 of the same coupling with the upper part 182. The periphery 190 illustratively comprises an arcuate edge portion 192 that is formed in complementarity with the inner surface 194 of the periphery 188 of the upper portion 182. Adjacent to the arcuate edge portion 192 is an illustrative stepped portion 196. The stepped portion 106 provides a slot 198 by extending the bottom panel 202 from the bottom 184 downward relative to the top 182. The slot 198 provides the spacing for the edge 200 of the periphery 188. Such an arrangement provides an appearance of a generally flush transition between the upper part 182 and the lower part 184. The inner surface 194 of the periphery 188 and the outer surface 204 of the periphery 190 can be coupled and joined by any conventional method. For example, the surface can be ionized to relax the propylene so that an adhesive can bond the structures. In addition, a moisture activated adhesive can be used to link the upper portion 182 to the lower portion 184. Detailed views of the engagement of the upper portion 182 and the lower portion 184 are shown in FIGS. 17 and 18. The conformity between the peripheries 188 and 190 are evident from these views. Such allow sufficient union between the upper part 182 and the lower part 184. The appearance generally flush between the transition of the upper part 182 and lower part 184 is also evident through these views. The variations between the illustrative modalities are shown in Figs. 17 and 18. For example, the upper surface 206 is substantially coaxial with the level plane 2089 in Fig. 17, while the upper surface 206 is angled with respect to the level plane 208. It is also appreciated that the description it is not proposed to be limiting for the shapes represented in the drawings. Rather, other complementarily formed coupling surfaces that produce such a transition between such top and bottom panels are contemplated to be within the scope of the invention herein. Such a coupling of the upper part 182 and the lower part 184 can produce a cavity 210, as shown in Figs. 16 to 19. Depending on the application, the cavity 210 may remain empty, or may contain a structure. For example, Fig. 19 shows a final view of the surface of tables 180 with a core support of lattice member 76 illustratively located therein. The lattice member core 76 can be of the previously described type and can be attached to the interior surfaces 194, 212 via conventional means, such as an adhesive, for example. Such a core structure can provide increased resistance to the table surface 180. In fact, such resistance can expand the use of the body of work to other applications besides the table surface. For example, such can be used as a floor, or a side paneling for a structure or a vehicle. It is contemplated that other such cores may be used in place of the lattice member. For example, a foam core or honeycomb core can be used in place of the lattice. An illustrative pressed board manufacturing line 300 is shown in Figs. 20 through 28. Line 300 is for manufacturing laminated pressed-board panels of the type shown in Figs. 1 to 3, and is indicated by the reference number 2, for example. The manufacturing process comprises the coupling of several layers of materials, illustratively layers 6 and 8 (see Fig. 1), heating and pressing the layers of a laminated composite panel alone, cooling the panel, and then cutting it. In the illustrative embodiment, line 300 comprises the following primary stages: unwinding and coupling 302 (Fig. 22), preheating 304 (Fig. 23), heat and pressing 306 (Fig. 24), cooling 308 (also Fig. 24) rolling station (Figs 25 to 28), and shearing and cutting 310 (also Figs 25 to 28). A top view of line 300 is shown in Fig. 21. It is appreciated that line 300 may be of a width corresponding to a desired width of the composite material. Fig. 21 also illustrates the arrangement of tandem of each of steps 302, 304, 306, 308, 310. The unwinding and coupling step 302 is shown in Fig. 22. In the illustrative embodiment, the materials used to form the composite are provided in rolls. It is appreciated that the materials may be supplied in another manner, but for purposes of the illustrated embodiment, the material will be represented as rolls. Illustratively, step 302 holds the rolls of each illustrative layer 6 and 8 in preparation for coupling. As illustrated, step 302 comprises a plurality of conduits 312 through 320, each of which is illustratively capable of holding two rolls, a primary roll and a backing roll for example. In one embodiment, it is contemplated that any number of ducts may be used, and such number may be dependent on the number of layers used in the laminated body. For this illustrative embodiment, line 300 is configured to manufacture a laminate composite panel 2 similar to that shown in Figs. 1 to 3. It is appreciated, however, that the utility of line 302 is not limited to making only that panel. Rather such a line is also capable of manufacturing any laminated panel that requires at least one of the steps as described hereinafter. The conduits 312, 316 and 320 each comprise a primary roll of 6 'and a backing roll 6". of layer 6. In this example, layer 6 is illustratively a non-oriented fibrous material. Similarly, conduits 314 and 318 each comprise a primary roll of 8 'and an 8"reinforcing roll of layer 9 which is illustratively the woven fiber layer. Each roll rests on a platform system 322 comprising a sensor 324 and a sewing device 326. The sensor 324 detects the end of a roll to initiate feeding of the backing roll. This allows the rolls to create a large continuous sheet. For example, once the primary roll of 6 'fibrous material is completely consumed by line 302, and sensor 324 detects the end of that primary roll 6' and causes the start of the 6 'reinforcing roll to be attached to the end of the primary roll 6 '. This same process works with the primary roll 8 'and the 8' reinforcement roll as well. To secure each roll of a particular material together, the sewing device 326 sews, for example, the end of the primary rolls 6 'or 8' with the start of the reinforcement rolls 6"or 8", respectively. The stitched rolls produce a secure bond between the primary rolls 6 ', 8' and the reinforcing rolls 6"and 8", respectively, thus forming the continuous roll alone. Illustratively, the sewing device 326 cuts and seams the seams of the ends of the materials to form the continuous sheet. As well, illustratively, the yarn used to sew the rolls together is made of polypropylene or other similar material that can be partially melted during the heating steps, thereby creating a high bond in the final panel. It is contemplated, however, any of the suitable threads that can be used which may or may not be of a polymer. Each conduit of step 302 is configured such that, as the material is removed from the rolls, each will form one of the layers of the laminated composite which ultimately becomes the press board panel. The layer of fibrous material 6 of the primary roll 6 'of the conduit 312 illustratively forms the upper layer with the material of each successive conduit 314 to 320, providing alternating layers of the layers 6 and 8 under the formation of layers, as shown in FIG. 321 and FIG. 22. Each roll of material is illustratively removed from under the conduits that exit in direction 327. The materials formed in the resulting layer leave layer 302 through 321, pass over bridge 318, and enter the preheating step 304. The preheating step 304, as shown in Fig. 23, comprises a furnace 323 which causes the air to heat up to about 115 degrees C (240 degrees F) in the composite layers. The furnace 323 comprises a heater-blower 330 which directs the heated air in the composite chamber 332 which receives the layers of material. This hot air removes moisture from layers 6, 8, as well as heats the layers much more to the inside of it. Because such materials are often hydrophobic, the removal of moisture causes the core of the materials to cool. The forced heat causes the center to be heated, even while the moisture is being removed. This preheating allows the process to become more efficient during the heating and pressing stage 306. Step 308 illustratively comprises a roller / belt system including rollers 333 that moves the belts 335, as shown in Fig. 23. Illustratively, these bands are located up and down the panel 2, defining at least a portion of the chamber 332. The bands 335 assist in pushing the panel 2 through the step 304 and continue to step 306. The composite layers preheated exit through the opening 334 of step 304 and enter the press heating step 306, as shown in Fig. 24. The preheated composite panel 2 enters the step 306 through the opening 336 and enters the the chamber 337. The preheating and pressing step 306 uses a roller progression incrementally spaced located spaced between the heating zones, thus reducing the spacing vertical in camera 337. The combination of heating and reduction rollers reduces the thickness of panel 2 by transforming it into a laminated composite panel 2 of desired thickness. For example, step 306 comprises pairs of spaced rolls 338, 340, 342, 344, 346, 348 through which the composite layers pass. The rolls are linearly spaced as shown in Fig. 24. In an illustrative embodiment, to make a 4 millimeter panel, the rolls 338 will initially be spaced to approximately 15 millimeters. Successively, the rollers 340 will be spaced approximately 12 millimeters, the rollers 342 will be spaced approximately 9 millimeters, the rollers 344 will be spaced approximately 6 millimeters, and finally, the rollers 346 and 348 will each be spaced to approximately 4 millimeters. This gradual progression of pressure reduces the stress on the rollers, as well as the belts 350, 352 that drive the rollers. Such bands 350, 352 generally define the top and bottom of the chamber 337 through which the panel 2 travels. Due to less stress that is applied to the belts 350 and 352 which drive the rollers 348, 340, 342, 344, 346, 348, such belts 350, 352 can be made of such materials as Teflon glass, different from conventional materials such as metal. Teflon bands absorb less heat than metal bands, so more of the Heat generated will be transferred to the lamination of panel 2, in contrast to production lines that use conventional metal bands. In an illustrative embodiment, steps 306 and 308 are approximately 10 meters long and approximately 4 meters wide. In an illustrative embodiment, located between each pair of rollers are a pair of surfaces or plates 354, 356 between which the panel 2 moves during the rolling process. Illustratively, plates 354, 356 receive hot oil or similar fluid. It is appreciated, however, that other methods for heating the plates can be used. In the present embodiment, however, the hot oil causes the plates 354, 356 to raise the core temperature of panel 2 to approximately 171 degrees C (340 degrees F). The combination of the compression force generated by the rollers 338, 340, 342, 344, 346 and the heat generated by the plates 354,. 356 causes the polypropylene in the layers of material 6, 8 to melt, causing the same to continue to fuse and compacting the panel 2 of the desired thickness. After the layers 6, 8 of the composite panel 2 are heated, melted, and reduced to a desired thickness, the resulting composite panel 2 is cooled in the cooling stage 308. In the embodiment illustrated, the cooling stage 308 is an extension of the stage of heating and pressing 306 to the extent that step 308 also includes pairs of rollers 358, 360, 362, 364, 366, which are similarly positioned to, and arranged linearly with, rolls 338, 340, 342, 344, 346, 348. The space between each of the rollers is approximately the same as the space between the last pair of rollers of the heating and pressing step 306, in this case the rollers 348. In the previous example, the rollers 348 they are illustratively spaced to approximately 4 millimeters. Accordingly, the spacing between the rollers of each pair of rollers 358, 360, 362, 364, 366 of step 308, through which the panel passes, is also spaced approximately 4 millimeters. Cooling stage 308 treats plates 372 through 406 which are cooled with cold water, illustratively at about 11 degrees C (52 degrees F), rather than being treated with hot oil, as is the case with the heating step and of pressing 306. This cooling step quickly solidifies the molten polypropylene, thereby producing a rigid laminated pressboard panel 2. The pressed table panel 2 leaves cooling stage 308 at outlet 408, as shown in FIG. Fig. 24, and enters the shearing and trimming stage 310 as shown in Figs. 25 through 28. In an illustrative embodiment, the composite panel 2 passes through an internal interior wall lamination stage 410 and the one in the stage cutting and trimming 412. When panel 2 passes through step 412, its edges can be cut to a desired width and the panel cut to any desired length with the panel exiting to platform 414. A top view of the line 30 is shown in the Fig. 21 including the various steps mentioned in the foregoing 302, 304, 306, 308, 310 as well as the finish in a step 416. This step 416 is illustratively for applying an acrylic finish or other similar resin to the surface of the composite panel . Specifically, once such a composite panel 2 leaves the shear and cut stage 310, it is supported on a plurality of rollers 418 and is positioned along the length of the platform 414 to move the panel 2 in the direction 420. In an illustrative embodiment, the panel 2 can be rotated in position, as shown in Fig. 28, to the finishing stage 416. For the panel 2 rotates, the movable hooks 422, 424, one at the proximal end of the platform 414 and the other at the distal end of platform 414, as shown in Figs. 21 and 28, both move concurrently to move the panel 2. The latch 42 moves to a corner of the panel 2 in direction 420 while the latch 424 moves to the other corner of the panel 2 in the direction 426, finally placing the panel 2 on platform 415 in step 416. It is appreciated, however, that it is not required to locate such a finishing step in an angle relative to line 300. Alternatively, step 416 may be linearly located with the remainder of line 300. Illustratively, before applying the acrylic finish to panel 2 in step 416, its surface is first prepared. The illustrative process for preparing the surface of the panel 2 is first to bind the surface to accept the finished coating. After sanding the surface of the panel 2, a wet coating of the resin is applied. Illustratively, the resin is polyurethane. The acrylic resin can then be cured with UV, if necessary. Such curing is contemplated to take as much as 24 hours if necessary. Initial cooling, however, can only take three seconds. Such an acrylic coating has several uses, one being the previously discussed dry erase board surface, as well as the outer side wall panels for recreational vehicles and pull-type trailers. It is further contemplated herein that other surface coatings may be applied in step 416 as is known to those skilled in the art. In another illustrative embodiment, the inner wall lamination stage 410, although the part of the line 300 can be used to create the panel wall panel compounds 2. When the manufacture of such a panel, rather the panel that passes to through stage 10, as is previously discussed panel 2 is laminated in step 410. In this illustrative embodiment, as shown in Figs. 25 and 26 for example, step 412 comprises an unwinding hopper 430, a hot air blower 432, and a roller stage 434. The hopper 430 is configured to illustratively support two rolls of material. For this illustrative embodiment, a base substrate layer 436, and a top surface material layer 438 are located in the hopper 430. It is appreciated that the base substrate layer 436 may be any suitable material, including the material layer fibrous 6 as previously discussed or a top quality surface material. The layer of finishing surface material 430 can be of any finishing or surface material such as vinyl, paper, acrylic, or fabric. The unwinding hopper 430 operates similar to that of step 302 to the extent that both are unrolled rolls of material. The hopper 430 operates differently from the step 302, however, to the extent that both layers 436 and 438 are unrolled concurrently, rather in tandem, similar to the rolls 6 'and 6", for example. In other words, both layers 436, 438 will form the composite top coat layers, rather they form a single continuous layer for a board, as is the case with roll 6 'and 6' ''. In the illustrative embodiment, the substrate layer base 436 is unwound below the top surface material layer 438 as shown in Figs. 26 and 27. In addition, both layers 436 and layer 438 form a composite as they enter the stage of roller 434. Hot air blower 432 blows hot air 438 about 232 degrees C (450 degrees F) in direction 448 between the layer 436 and layer 438. This causes the surfaces, particularly the surface of the base material layer 436, to melt. For example, if the base substrate layer 436 is the layer of fibrous material 6, the polypropylene on the surface of this material is melted. As the layer 436 and the layer 438 pass between a pair of rollers 450 in the roller stage 434, the molten polypropylene of the layer 436 joins the layer 438, forming a composite of fibrous material having the finished surface material 438. After the materials have formed a laminated composite, then they can proceed to the shearing and cutting step 310. It is contemplated that the finishing surface material layer 438 may comprise various finishing materials applied to the base material layer. 436 either concurrently or in tandem. For example, a roll of material layer 438 may comprise a roll that includes a section of vinyl, attached to a section of paper, and then to the cloth and then to the vinyl again. The unwinding of this roll and bonding and bonding in step 436 produces a single composite board having several finishing surfaces placed in a tandem manner which can be sheared and cut in step 310 as desired. Another manufacturing line of the illustrative pressed board 500 is shown in Figs. 29 and 30. Line 500 is another embodiment for the manufacture of laminated pressed-board panels of the type illustratively shown in Figs. 4 to 6. This manufacturing line 500 is similar to the manufacturing line 300 previously discussed, wherein the process 500 comprises the coupling of several layers of materials, illustratively the layers 22, 24 as well as the calendering surface 32 and the coated surface 34, as illustratively shown in panel 30 of FIG. 6. Manufacturing line 500 comprises the following steps of panel manufacture: unrolling and coupling steps 502, preheating step 504, heating step and pressing 506, the cooling step 508, the calendering step 510 and the shearing and cutting step 512. An illustrative embodiment of the line 500 comprises a calendering step 510. This step is located in the same location as the step of lamination 410 of line 300, as shown in Fig. 25. The purpose of the calendering step is to smooth the top surface of the panel illustrative 30 to prepare it for the paint application of line 514. Conventionally, the use of the bands 350, 352 in conjunction with the heated plates can cause the texture of those bands, similar to a cloth pattern, which is embedded in the surface of panel 30. (See, also, Fig. 24). The calendering process removes this pad to provide a smoother surface in anticipation of the application of the paint. In the illustrative embodiment shown in Fig. 30, the calendering stage 510 as a transport line 570 and the spaced rollers 572, as well as a heat source 534. As the panel 30 leaves the cooling stage 508, it is transferred. to the calendering stage 510 where the heat source, illustratively infrared heat or heated air, or a combination of both, is applied to the surface of the panel 30. The panel 30 is then directed between the two spaced rolls 572 which will then smooth the surface that has been heated by the heater 574. In one embodiment, it is contemplated that at least one of the rollers be temperature controlled, illustratively with water, to maintain the rollers up to about 49 degrees C (120 degrees F) approximate. It is further contemplated that the heated air or the IR heater be controlled to only heat the surface of the panel 30 and not the center of the table itself. In addition, it is contemplated that the roller can be subjected to a force 270 pounds per approximate linear inch on the surface of the panel 30 in order to smooth any pattern on the surface and / or related defects thereon to produce a calendered surface 32 as previously discussed with respect to Fig. 6. It will be appreciated that this calendering process will prepare the surface 32 of the panel 30 so that it can receive a Class A self-finishing. Once the panel 30 leaves the calendering stage 510, it is then transferred to the shearing and cutting step 512 where the Panel will take its final form before the painting stage. In contrast to the manufacturing line 300, however, the line 500 further comprises the paint application line 514. The paint line 514 comprises a transfer conveyor 516 that moves the panels, in this illustrative case panel 30, from the shearing and cutting step 512 to the paint line 514. This is illustrated illustratively by the rollers on the conveyor 518 that move the panel 30 perpendicularly from the shearing and cutting step 512 to the paint line 514 which is illustratively , placed parallel to the line 500. If, for example, the panel 30 or the other panels 20 and 28 do not receive a paint application, they can be removed from the line at a discharge point 520. If the panel 30, for example , will be receiving a paint application, it is loaded onto the paint line 514 via a step forming section 522 as shown in Fig. 29. The first step of the painting process of the paint line 514 is to flame-treat the upper surface of the panel 30 in 524. The flame treatment process is a means to relax surface tension and load ionize the board for chemical bonding. This will decrease the tension of the surface of the plastic or the bonding material. Such a decrease in surface tension allows the plastic to have a surface tension similar to that of the paint that will create better adhesion of the paint to the board. In the illustrative embodiment, the flame treatment uses a blue flame about 1/4 inch in height and the board is passed down the flame about 4/8 of an inch at a rate of about 26 feet per minute. It is appreciated, however, that other means for heating the surface of the panel 30 are contemplated and, with respect to the flame size, temperature, and distance of the flame table, is illustrative and is not considered to be the unique embodiment of the flame. this description. It is contemplated that much of the paint line will be enclosed and, due to that, after the flame treatment step 524, an air inlet section is added to create positive pressure within the line. In the illustrative mode, a fan is added to this Section for the intake air that will blow dust and dirt away from the panel to keep it clean. The next stage of the paint line 514 is the spray booth 528. The booth 528 applies a plastic primer to the surface of the panel 30 that integrates with the plastic on the board to assist in the best adhesion of the layers. of subsequent paintings. In this illustrative embodiment, a sprinkler downwash is applied to the surface of the panel 30. Leaving the car 528, another air inlet section 530 is illustratively located to additionally create positive pressure to continue to prevent dust and other contaminants. that sits on the surface of the panel. After the panel 30 leaves the adhesion promoting booth 528, it enters the UV primer sealing spray booth 532. The booth 532 applies a UV refill paint to further level the surface of the panel 30, as well as serving as an additional primer for UV care paint. It is appreciated, however, that depending on the application of the panel, the UV filler can be replaced with a UV paint or another paint as a final coat. In this illustrative embodiment, however, booth 532 uses a downstream current spray to apply the top seal on panel 30.

Leaving the cabin 528, the panel 30 then enters an instantaneous environmental vaporization stage 534 where the panel 30 remains to allow the paint solvents to evaporate. Although not shown, the solvents are removed from the instantaneous environmental vaporization step 534 where the solvents burn to avoid entering the atmosphere. In addition, step 534 may include an inlet fan 536, similar to air inlets 526 and 530 to maintain positive pressure in this section. After allowing the solvents to dissipate from the surface of the panel 30, it is transported under a UV curing lamp 538 to further cure the paint. The curing of UV 538 is illustratively a UV, of high intensity at which the paint is sensitive, and which will further cure the paint. After passing through the UV curing 538, the panel 30 is passed through an infrared oven 540. The panel 30 is moved through the oven 540 in an illustrative ratio of 2.5 meters per minute and the IR furnace is adjusted to approximately 74 degrees C (165 degrees F). This stage additionally assists in driving any of the remaining solvents that might not have been driven out before UV curing. In addition, those solvents are also then sent and burned before reaching the atmosphere.

Once it exits from the IR 540 furnace, the panel 30 is transferred to a lateral transfer section 542 which already allows the removal of the panel 30 if the paint applied in the cabinet 532 was the final application of paint, or through conveyors 544 This is shown in Fig. 29, if the panel 30 is to be transferred to a secondary paint line 546. If the panel 30 is transferred to the secondary paint line 546, it is passed through another spray booth. 548. The booth 548 uses a downflow spray to apply a final coat on top of the UV filler layers and the adhesion promoter discussed above. The final UV layer will be the finished layer that provides the Class A auto finish as previously discussed, for example. Once the final layer has been applied on the surface of the panel 30, the following process is similar to that described with respect to the paint line 514 which is that the panel 30 again undergoes an instantaneous environmental evaporation in the section 550, similar to the environmental instantaneous evaporation step 534 previously discussed, where the solvents are allowed to evaporate, and are removed and burned. In addition, the panel is transferred through a curing section with UV 552, similar to that of 538 and as previously described, curing with UV 552 also serves as high light.

UV intensity to further cure the final layer applied on the 548. After passing through the UV section 552, the panel 30 then enters the infrared oven 554, which is similar to the IR 540 oven previously discussed, wherein the The panel is subjected to a temperature of approximately 74 degrees C (165 degrees F) for approximately 2.5 minutes. When the panel 30 leaves the IR furnace, it enters an inspection booth 556 where the surface is inspected for defects in the paint or the board. The inspection can be either manually achieved for visual inspection of the surface and identification of such defects, or it can be achieved through an automated inspection process comprising sensors to locate defects, etc. In addition, inspection cabin 556 also serves as a cooling process for the process. Inspection booth 556 maintains a temperature of approximately 25 degrees C (78 degrees F) with approximately 50 weight percent relative humidity to cool at least the surface of the table to approximately 74 degrees C (165 degrees F) of the furnace Go to approximately 27 degrees C (80 degrees F). If a table does not pass the inspection, it will be removed for repair or recycling. If the table passes the inspection, it will pass through a pressure roller 558 that will apply a slip sheet that is illustratively a sheet of thin 4 millimeter polypropylene that protects the painted surface of the panel 30 and allows it to be stacked in the discharge section 560. Composite materials similar to those used for the manufacture of automotive bodies and interiors, have the potential to be recycled in New Materials. An impediment to such recycling, however, is the incompatible particle sizes of the otherwise potentially recyclable constituents. For example, a variety of combinations of polypropylene, vinyl, polyester, ABS, and fibrous materials can be used to produce a panel or core product for a panel. In the recycling system 600, shown in Figs. 31 through 33, various materials are collected and segregated based on a desired composition at 602. Each material is granulated to reduce its particle size. The degree to which each material is granulated can be varied depending on the desired chemistry in the resulting panel. After each material is granulated, the loss and weight is determined at 604. This is done so that the cross section and the weight can be controlled before the resulting material is laminated to a panel. The materials are mixed in a composition at 606 and transferred to the harvester 608. The composition is then transfers from the harvester 605 through a metal detector 612 that is configured to remove the metal particles. The remaining composition is then deposited in a dispersion box 614. The dispersion box 614 allows particles of a particular maximum size to be deposited on the granulated web 616. The loss and weight of the resulting composition is then determined again to maintain the density of the final panel. The composition is then transferred to the storage of recycle composition 626 in advance to deposit it with the other laminated constituents. The recycled composition manufacturing panel line 618, shown in Figs. 32 and 33, is similar to line 300 shown in Fig. 20. Line 618 comprises the following primary stages: unwinding 620, preheating 622, heat and pressure 624, storing recycled material 626, cooling 628, shearing and cutting 630 In the illustrated embodiment of Fig. 32, the rolls 632, 634 of the material, such as fibrous or woven glass material, for example, are located in step 620. The rolls 632, 634 are unwound to form the composite layers . These layers are then preheated using the pre-heater stage 622, similar to step 604 used in the manufacturing line 300. The recycled composition material of step 626 comes out in the form of chips that it has an irregular shape with a maximum dimension in any one direction of, illustratively, 0.125 inches, and then it is deposited between the composite layers. The new composite layers are then subjected to the same heat, pressure and cooling in steps 624 and 628, respectively, as to the heat and pressure stage 306 and the cooling stage 308 of the manufacturing line 300. The step of The heat and pressure 624 receives the preheated composite layers, and through a progression of rollers, which are reduced in an incrementally spaced manner, compresses the composite layers to a desired thickness similar to that discussed previously. Again, this gradual progression of pressure reduces the stress on the rollers and the bands that drive the rollers, as discussed with step 306 of line 300. In addition, the bands that drive the rollers can also be made of material from of Teflon glass, different from a metal, also previously discussed. Also similar to step 308, step 628 includes a pair of surfaces or plates between each two pairs of rollers to allow the composite layer to move therebetween. Illustratively, the plates receive hot oil. It is appreciated that other methods for heating the plates are contemplated, similar to step 306. After the composite layers are heated, melted, and reduced to a desired thickness, the resulting panel is cooled. The stage of cooling 628 is comparable to step 308. The final stage is shearing and cutting 630, which is also similar to the shearing and cutting step 310 of line 300. Cornos is shown in Figs. 32 and 33, line 618 further includes a double side lamination step 636. Step 636 is similar to step 410, shown in FIG. 25 except for the additional unwind step 638 located below a primary unwind stage 637. It is contemplated that applying a surface on both sides of a composite panel is the same as applying a single surface, as shown in Fig. 20, with the exception that hot air will be directed to both sides of the composite panel. The process as shown in Fig. 20 applies to the bottom surface as well. A sectional view of the layer of fibrous substituted material 6 is shown in Figs. 36a a la c. The distinction between the views of Figs. 36a to c is the amount of heat applied to the layer of fibrous material 6. As previously discussed in the foregoing, the layer of fibrous material 6 illustratively comprises a mat illustratively of about 25 weight percent hemp and about 25 weight percent kenaf with the remainder being illustratively polypropylene. The fibers are randomly oriented to provide a specific orientation of resistance. Variations of this fibrous material are contemplated, including a combination of about 25.74 percent by weight of hemp and about 24.75 percent of kenaf with about 50 percent by weight of polypropylene and about 0.05 percent by weight of maleic anhydride. Other such fibrous materials can also be used, such as flax and jute, for example. It is also contemplated that other mixing ratios of the fibrous material can be used. It is further contemplated that other binders which in place of the polypropylene may also be used for the purpose discussed further herein. Still further, it is contemplated that other fibrous materials having high process temperatures above about 204 degrees C (400 degrees F), for example may also be used. The layer of fibrous material 6 shown in the approximately 36a is considered a virgin version of the layer, similar to that shown in Fig. 1, or on the 6 'and 6"rolls shown in Fig. 22. This version of layer 6 is considered virgin, because it has not been subjected to a heat treatment or compressed. The fibers and the binder that make up the layer exist as essentially separate constituents simply mixed together. In this state, the virgin version is highly permeable and stackable. The relative thickness 700 of the layer 6 is relatively greater than the thicknesses 702 or 704 of the layers 6 shown in any of Figs. 7b and 7c respectively. In addition, because the binder, polypropylene, for example, does not bind to the fiber, the heating layer 6 can cause it to consolidate or contract, particularly in its length and width. In contrast, layer 6 shown at 36c, although comprising the same constituents as layer 6 in Fig. 36a, has been subjected to considerable heat and pressure. This modality of layer 6 is considered a high density version. In this case, the binder has been completely wetted. Completely moistened for the purposes of this discussion means that the binder has for practical purposes, all liquefied and bonded to the fibrous material of layer 6. Such produce an essentially non-permeable density and rigid body. The binder, typically thermal fusion polymer, similar to polypropylene, melts in a liquid state, causing the polymers to adhere to and / or wet the fibrous materials. This can lead to a consolidation of the compound when it cools, which shrinks the layer. This results, however, in a rigid, dimensionally stable flat sheet. If such a layer then overheats, because the binder has already bonded with the fibrous material, the layer does not will contract, different from layer 6 described in Fig. 36a. Such high density layers are used to produce the layers 72, 74 of the lattice composite 70, previously discussed with respect to Fig. 10, for example. The version of layer 6 shown in Fig. 36b, in contrast to the both virgin and high density versions in Figs. 36a and c, respectively, is considered a low density version. This low density version has been subjected to heating and pressure, so that a portion of the binder in the layer has been moistened, different from the virgin version of Fig. 36a which has been subjected to such a process, in addition, different from the high density layer shown in Fig. 36c, the low density layer binder has not been completely wetted. In other words, not all of the binder in the low density layer has been liquefied and bonded to the natural fibers, only a portion of the binder has. The remaining binder is still kept stopped from the fibrous material. This makes the rigid low density version similar to the high density version, still, also semipermeable, more similar to the virgin version. In an illustrative embodiment, the binder has been melted and wetted in about 50 percent of the fibers that are in the layers. In this case, it is not believed that the fibers per se have grown, nor changed in a specific value. Rather, the fibers they have precisely absorbed the binder. The low density version can provide accelerated processing for three-dimensional molding, particularly in molding, similar to that shown in Figs. 11 and 12, where several compression zones are used to form the material. In addition, using such a compound provides lower production costs. In addition, because the layer is rigid, it still has a permeability, it can be used as a table for advertisements alone or in conjunction with the dry erase table 150 of Fig. 15, for example. The properties also make it conductive for sound insulation or ceiling tiles. Conventional heat sources such as infrared ovens are not used to heat a high density layer material 6, because it can cause changes to its physical dimensions or cause superheating of the surface air of the high density layer 6 in order to Take the core of appropriate processing temperatures. In contrast, contact heating ovens, which use upper and lower heated plates to hold a virgin layer 6 under pressure during heating to prevent significant shrinkage, are not readily available in the general molding industry that can use such materials. In addition, the objective cycle times required to heat these layers at temperatures Molding requires extra energy and equipment. Using the low density version of the layer 6 can, in the balance, be a more cost effective way, to mold such layers of fibrous material. For example, a square sample of 1800 grams per meter of fibrous material, as described with respect to Figs. 26 to c, it may require approximately 83 seconds of heat time in a contact oven to obtain the virgin version up to the molding temperature. The high density version requires 48 seconds of heating time in an IR oven. The low density table, however, may only require approximately 28 seconds of heating time in a hot air oven circulated by air. This is to achieve a core temperature of approximately 171 to 176 degrees C (340 to 350 degrees F). When heating the low density version in a hot air oven circulated by simple air, the energy required to heat the low density board is 50 percent less than the energy required to heat the layer through a kiln. contact and 70 percent less than the energy required to heat a consolidated pressboard using the infrared oven. The high density layer is typically uniquely heated by an infrared oven. This is due to The high density version does not have permeability for hot air, and the contact furnaces can overheat and damage the layer. Some benefits of the high density version over the virgin version are also found in the low density version. First of all, similar to how the high density version requires less packaging space than virgin due to its reduced thickness, the low density version also requires less packaging space since its thickness is also less than that of the virgin version . Such translates into reduced shipping costs. Second, because the low density version is rigid, similar to the high density version, the low density version can be handled much easier with mechanical devices, such as fasteners and presses. This can be more difficult with the virgin version that is more foldable. Also, low density material does not always have to be preheated. Some applications of the virgin version may require that the layer be preheated to dimensionally stabilize the material. This is not necessary with the low density version. In contrast, for those production lines that use a needle system to handle the materials, particularly, for materials similar to the virgin version of layer 6, the high density version would not receive such needles, due to the solidified binder. The low density version, however, is still semipermeable, can receive such needles, allowing it to be easily transported, similar to that of the virgin version. The manufacture of the low density version similar to that shown in Fig. 36c comprises subjecting the virgin version to both heat and pressure. The heat and pressure are provided illustratively by an oven comprising rollers that prick the material to reduce its ability to shrink while being heated. The rollers have bands with holes placed between them, through which hot air passes. The layer that is being heated as structurally rigid as possible in this way does not absorb and becomes narrow and wide in the middle. The heat and pressure cause the binder to liquefy, and under the rollers, it causes the binder to melt which is absorbed into and surrounding the natural fiber. The layer can contract some minor degree, but it can be compensated during this manufacturing process. When the layer is removed from the oven, the cold air is blown over it to solidify the layer. Typically, thermal fusion polymers are sensitive to heat, and at temperatures above 115 degrees C (240 degrees F) they will try to contract (deform). Therefore, opposite permeable bands that have pressures Opposites limit the amount of heat sinking contraction that will occur during this process. Once the initial heating has occurred (polymers changed from a solid to a liquid state), and consolidation of the thermal fusion and non-thermal fusion fibers are achieved, the consolidation layer 6 becomes dimensionally stable thermally. After heating, and while the consolidating mat is under compression between the opposing air permeable bands, the layer is cooled by ambient air which is equally applied on the opposite sides of the consolidated mat, again, to carry the thermal fusion polymers back to a solid state. Additional embodiments of the present disclosure comprise structural mats and resulting panels that one embodiment have thermal deflection characteristics, in another embodiment have high strength characteristics, and in another embodiment have thermal deflection and high resistance characteristics. It is appreciated that the thermal deflection / high strength characteristics are exhibited in the panel form of the structural mat. It is further appreciated that the percentages disclosed herein are percentages by weight. A first illustrative embodiment is a nucleated polypropylene composition wherein the nucleated material is an amorphous aluminosilicate glass. He Nucleated polypropylene can be added to the additional and synthetic fibers to form a structural panel. In an illustrative embodiment about 1% nucleated material is added to the polypropylene content. An example of such aluminosilicate glass nucleated material is sold under the tradename Vitrolite® by the NPA Corporation. Vitrolite® can reduce the size of the polypropylene molecule, and can thus increase the thermal deflection of the panels by approximately 15% and 20%. The Vitrolite® can also substantially improve the impact strength of the panel by moderately improving its flexural or tensile strengths. The impact resistance (amount of energy applied to the sample failure) can be increased between 25% to 50% over non-nucleated formulations of the same equipment and weights. It is appreciated that other nucleated agents can be used herein in alternative embodiments. An example of such improvements can be observed when comparing two equal formulations of the same weight in grams, type of polypropylene base used in the percentage of the formulation and the same percentage and type of the natural fiber. The only difference in the formulation in the test, sample 2 contains 1% nucleated additive in the polypropylene content of the formulation. Sample 1 contains non-nucleated additive, but includes all other substrates in portions and exact types. Both tested formulations contained 50% polypropylene and 50% natural fiber. The samples were prepared using a cardante / crossover process by which the materials were mixed homogeneously in a composite sheet. These results are as follows: Samples: 1. Standard 2. Nuclear Flexural Module 248,000 psi 330,000 psi Resistance to 3,065 psi 3,550 psi Voltage Thermal Deflection 156 Celsius 169 Celsius @ 66 psi Impact Energy 3.00 in-lbf 4.00 in-lbf Data assembled are based on 10 sample runs per production lot number. There were three runs of lot numbers, for a total of 30 samples. The percentage of the material types in the formulation can vary from about 40% nucleated polypropylene to about 40% natural fiber. Formulations outside the upper and lower percentage blend limits are not considered practical since they can not provide any increased material value or application. Another illustrative embodiment is a fiber mat comprising a coupling agent, such as maleic anhydride in solution. For example, a composition Illustrative may comprise about 7% maleic anhydride content in solution added to the mixture of about 50% polypropylene and about 50% natural fiber. The mixed polymer ratio to be applied is about 4% coupling agent with about 96% polypropylene material. The 7% maleic anhydride content of the coupling agent improves both the polymer graft and the surface bond between the polymer and the natural fiber, which can double the strength of the panel. An illustrative example of such material is sold under the trade name Optipak 210® by the Honey ell Corporation. Maleic anhydride can improve the polymer graft and the surface bond between the polar and non-polar materials, and thus, can increase the total mechanical strengths of the panels by approximately 75% and 100%. It is appreciated that other coupling agents can also be used. This formulation in combination with the fiber material forms the panel, according to the means discussed further herein. It is further appreciated that the material can be natural or synthetic fibers and is randomly oriented or woven. An example of such improvements can be observed when comparing two equal formulations of the same weight in grams, type of polypropylene base used in the percentage of the formulation and in the same percentage and type of natural fiber. The only difference between the formulation and the samples is that sample 2 contains 4% maleic coupling additive in the polypropylene content formulation. Sample 1 contains non-coupling additive, but includes all other substrates in exact portions and types. Both tested formulations contained 50% polypropylene and 50% natural fiber. The samples were prepared using a conventional cardante / crossover stacking process by which the materials were mixed homogeneously into a composite sheet. Their results are as follows: Samples: 1. Standard 2. Coupled Flexional Module 248,000 psi 450,500 psi Resistance to 3,065 psi. 7,750 psi Voltage Thermal Deflection 156 Celsius 161 Celsius @ 66 psi Impact Energy 3.00 in-lbf 1.75 in-lbf The data collected is based on 10 sample runs per production lot number. There were three runs of lot numbers, for a total of 30 sample. The percentage of the material types in the formulation can vary from about 40% polypropylene coupled with about 60% natural fiber to about 60% polypropylene coupled with about 40% of natural fibers. Another illustrative embodiment comprises a combination of core / binder material and coupled coupled / binder material blended with a fibrous material for a structural mat forming a thermal deflection / high strength panel. Illustratively, the combination of Vitrolite® as the nucleating agent and Optipak 210® as the coupling agent can create a high strength / high thermal deflection panel. An illustrative embodiment comprises approximately 4% of the coupling agent and about 1% of the nucleating agent in the complete composite mixture. To achieve this mixture, the formulation is comprised of approximately 25% nucleated polypropylene with approximately 2% Vitrolite® additive and approximately 25% polypropylene coupled with approximately 8% Optipak 210® additive. The rest is approximately 50% natural fiber. The constituents are combined and rotated to form a 2% nucleated polymer fiber, with an 8% coupled polymer fiber blended with the natural fiber (and / or synthetic fiber), either woven or random, to form a mat. of deflection of high temperature, high resistance and impact resistance on the table. The combined formulation retains some of the thermal deflection and resistance achieved independently by the compositions nucleated and coupled. An example of such improvements can be observed when comparing three equal formulations of the same weight in grams, type of polypropylene base used in the same percentage of formulation in the same percentage and type of natural fiber. The only difference in the formulation between the samples is that sample 1 contains 1% nucleated additive in the polypropylene content of the formulation, sample 2 contains 4% additive coupled to the polypropylene content of the formulation, and the sample 3 contains a mixture of 1% polypropylene additive nucleated in 2% of the total mixture and 4% of additive coupled in 25% of the total mixture. All 3 formulations tested contained 50% polypropylene and 50% natural fiber. The samples were prepared using a conventional cardante / crossover stacking process during which the materials were mixed homogeneously into a composite sheet. Your results are as follows: As these results demonstrate, the combined panel (Sample 3) exhibits a flexural modulus and tensile strength comparable to the coupled panel. The combined panel also exhibits thermal deflection and impact resistance comparable to the nucleated panel. The results demonstrate that the characteristics of both the nucleated / binder fiber panel and a coupled fiber / binder panel can be present in a combined nucleate / binder and coupled / binder panel. The results show that the combined sample has coupled and nucleated properties that are as pronounced as the individual samples. This may be due to the fact that fewer coupling and nucleating agents are used in the combined sample than the individual samples. Illustratively, by achieving the total values of mechanical strength, thermal deflection and complete compensation of the negative impact strength due to the coupling agent, includes a formulation comprising approximately 25% polypropylene with approximately nucleated additive, approximately 25% polypropylene with approximately 8% coupling additive combined with approximately 50% natural fiber. Other formulations containing any ratio up to the maximum adhesive of about 2% nucleated and about 8%. The coupling provides improvements in both mechanical strength, impact resistance and thermal deflection when comparing the standard mixture formulation as it contains non-nucleated / combined coupled or nucleated or singular coupled. The percentage of the types of materials in the formulation can vary from about 40% polypropylene nucleated / coupled with about 60% natural fiber to about 60% polypropylene coupled nucleated with about 40%, natural fibers. Another benefit of such a panel may be in the total deduction in mass weight to meet the resistance and application performance requirements. For example, a composite application of 180 grams per square meter (gsm) that meets specific data requirements can reduce to 1200 gsm in total weight and still meet the same data requirements. This can result in approximately a 33% reduction in material weight and provide additional cost benefits either in the compound or in the end use such as part weight reduction, which in turn provides weight of reduced vehicle resulting in improved fuel mileage and reduced cost to operate on a per-mile basis throughout the life of the vehicle. It is also notable that the coupling of the fiber can improve the graft strength between polar and non-polar substrates which are synthetic fibers such as polypropylene or polyesters or natural fibers such as hemp, jute, kenaf, tose and other similar fibers. Maleic anhydride serves this function. This can decompose the non-polymer fiber surfaces to allow impregnation of the polymer surface when it is in the liquid state. It is further noted that natural fiber, glass, other types of fibers or flexible materials, whether woven or non-woven, can be used. An illustrative manufacturing process for the structural mat compositions comprises adding the aluminosilicate glass and maleic anhydride to polypropylene pellets to form polypropylene fibers. In this case, however, the nucleated polypropylene fibers are made completely separate from the coupled polypropylene fibers. It is appreciated that the addition of both a nucleating agent and a coupling agent together with the polypropylene in a system alone will not work. It has been found that by adding both the nucleating and coupling agents to the polypropylene to form the fibers causes the polymer chains to break because the polypropylene could not accept too much additive. Several attempts were made to combine both a nucleating agent and a coupling agent with polypropylene for fiber production. The combination of the material alters the molecular weight of the polymer by reducing the liquid viscosity to a point that continuous fiber filament productions were not possible. Accordingly, two separate systems are created, as is illustratively shown in Fig. 37. This graph shows the illustrative process for making a pressed board panel of structural mat 800. The process comprises making the polypropylene fibers as indicated by the number reference 802, manufacture a fibrous mat as indicated by reference number 804, and manufacture the panel as indicated by reference number 806. The first mixing system 808 makes the nucleated polypropylene fibers. Here the polypropylene pellets 810 and the nucleating agent (eg, aluminosilicate glass) 812 are combined into 814, extruded into 816, spun into 818, removed and terminated into spin at 829, and prayed and cut into polypropylene fibers nucleated in 822 of conventional size • used in natural fiber mats. Similarly, the second mixing system in 824 makes the maleic or coupled polypropylene fibers. Here the polypropylene pellets 16 and the coupling agent (for example) maleic anhydride) in 828 are combined in 830, extruded in 832, spun in 834, withdrawn and finished in 836 yarn, and crimped and cut into fibers polypropylene nucleated in 838 of conventional size used in natural fiber mats. In this illustrative embodiment, about 4% of the nucleated polypropylene fiber of system 408 is aluminosilicate glass with the remainder being propylene. In system 824, about 16% of the coupled polypropylene fiber is the coupling agent, maleic anhydride, with the remainder than polypropylene. In the illustrated embodiment, a blend of about 25% discrete nucleated polypropylene and 25% discrete appropriate polypropylene and 25% discrete coupled polypropylene are added to the mat fiber to begin forming the structural mat. A nonwoven structural mat is formed at 804 according to the methods discussed at least partially in the foregoing and known to those skilled in the art. The mat fiber is mixed with the nucleated / coupled polypropylene at 840. The nonwoven structural mat can be reported as desired at 842. It is appreciated that during the mixing process at 840, a mixture Generally homogeneous nucleated polypropylene and coupled polypropylene occur. Once the mats are formed, they are available for three-dimensional molding to form a pressed board panel or structure molded at 806. As is illustratively shown, and as at least in part previously discussed, as well as known to those skilled in the art. technique, the structural mat is raised to the melting temperature of the polypropylene at 844 and either it is compressed into a flat panel or it is molded into a three dimensional shape at 846. The resulting panel exhibits thermal deflection and high strength, as indicated at 846. It is believed that during thermal processing, the homogeneous mixture of maleic polypropylene fibers and nucleated polypropylene fibers flow together when they are in the fusion stage allowing the molecules of each to combine, creating a unique combined chemical that is not Believe possible using the conventional extrusion methodology. Although the present description has been described with reference to particular means, materials and modalities, from the above description, one skilled in the art can easily determine the essential characteristics of the present description and several changes and modifications can be made to adapt the various uses and characteristics without departing from the spirit and scope of the present invention as set forth in the following claims.

Claims

CLAIMS 1. A structural mat for manufacturing a structural mouldable pressed table panel, the structural mat characterized in that it comprises: a nucleated / coupled binder material comprising: a first binder material combined with a nucleating agent; a second binder material combined with a coupling agent; wherein the first binder material combined with the nucleating agent makes a discrete nucleate / binder material and the second binder material combined with the coupling agent makes a discrete coupled / binder material; and wherein the discrete nucleate / binder material and the discrete coupled / binder material are mixed together; and a fibrous material blended with the discrete nucleate / binder material and the discrete coupled / binder material, and formed in the structural mat.
2. The structural mat according to claim 1, characterized in that the first and second binder materials are each polypropylene, and in wherein both the discrete nucleate / binder material and the discrete coupled / binder material are in fibrous form.
3. The structural mat according to claim 2, characterized in that the first binder material combined with the nucleating agent further comprises approximately 4% nucleating agent with the remainder being the first binder material.
4. The structural mat according to claim 2, characterized in that the second binder material combined with the coupling agent further comprises approximately 5% coupling agent with the remainder being the first binder material.
5. The structural mat according to claim 2, characterized in that it further comprises approximately 25% discrete nucleate / binder material.
6. The structural mat according to claim 5, characterized in that it further comprises approximately 25% discrete coupled material / binder.
7. The structural mat according to claim 6, characterized in that it also comprises approximately 50% fibrous material
8. The structural mat according to claim 2, characterized in that it further comprises about 25% discrete nucleate / binder material with about 2% of the structural mat which is the nucleating agent, about 25% discrete coupled material / binder with about 2.5% of the structural mat which is the coupling agent and approximately 50% fibrous material.
9. The structural mat according to claim 2, characterized in that the nucleating agent is an aluminosilicate glass.
10. The structural mat according to claim 9, characterized in that the coupling agent is maleic anhydride.
The structural mat according to claim 2, characterized in that the discrete nucleate / binder material and the discrete coupled / binder material are homogeneously mixed 12.
The structural mat according to claim 2, characterized in that the fibrous material is a material randomly oriented.
The structural mat according to claim 12, characterized in that the randomly oriented fibrous material is a natural fiber material.
14. The structural mat according to claim 2, characterized in that the fibrous material is a woven material.
15. A structural panel having high strength and high thermal deflection properties, characterized in that the panel comprises a rigid body of solidified nucleated / coupled binder material and a fibrous material, each dispersed throughout the thickness of the body; wherein the solidified nucleated / coupled binder is formulated from a nucleated material with a binder and a material coupled with a binder.
16. The structural panel according to claim 15, characterized in that the nucleated / coupled binder material comprises polypropylene.
17. The structural panel according to claim 16, characterized in that it also comprises approximately. 50% nucleated / coupled polypropylene comprising about 4% nucleating agent and about 5% coupling agent, and about 50% fibrous material.
18. The structural panel according to claim 15, characterized in that the nucleating agent is an aluminosilicate glass.
19. The structural panel according to claim 15, characterized in that the coupling agent is maleic anhydride.
20. The structural panel in accordance with the claim 15, characterized in that the fibrous material is a randomly oriented fibrous material.
21. The structural panel according to claim 15, characterized in that the randomly oriented fibrous material is a natural fiber material.
22. The structural panel according to claim 15, characterized in that the fibrous material is a woven material.
23. The structural panel according to claim 15, characterized in that the nucleated / coupled polypropylene is in a concentration of about 40% to 50%.
24. The structural panel according to claim 23, characterized in that the fibrous material is in a concentration of about 50% to 60%.
25. A method for making a structural mat for manufacturing a structural moldable structural board panel, the method characterized in that it comprises the steps of: combining a nucleating agent with a first polypropylene material; forming a solid fibrous combination of nucleating agent and the first polypropylene material; combining a coupling agent with a second polypropylene material, separated from the nucleating agent mixed and the first polypropylene material; forming a solid fibrous combination of coupling agent and the second polypropylene material; mixing the solid fibrous combination of nucleating agent and the first polypropylene material with the solid fibrous combination of coupling agent and the second polypropylene material; mixing a fiber material with the mixed solid fibrous combination of the nucleating agent and the first polypropylene material and the solid fibrous combination of the coupling agent and the second polypropylene material; and forming a structural mat by combining the fiber material with the mixed solid fibrous combination of the nucleating agent and the first polypropylene material and the solid fibrous combination of the coupling agent and the second polypropylene material.
26. The method according to claim 25, characterized in that it further comprises the step to formulate the nucleating agent and the first polypropylene material with about 4% nucleating agent and the remainder being the first polypropylene material.
27. The method according to claim 26, characterized in that it further comprises the step of formulating the coupling agent and the second polypropylene material with about 5% coupling and the rest which is the second polypropylene material.
28. The method of compliance with the claim 27, characterized in that it further comprises the step of providing about 25% nucleating agent and the first polypropylene material.
29. The method of compliance with the claim 28, characterized in that it further comprises the step of providing approximately 25% coupling agent and the second polypropylene material.
30. The method of compliance with the claim 29, characterized in that it further comprises the step of providing approximately 50% fibrous material.
31. The method according to claim 25, characterized in that it further comprises the step of providing about 25% nucleating agent and the first polypropylene material with about 2% of the structural mat which is the nucleating agent, about 2.5% of coupling agent and the second polypropylene material with about 4% of the structural mat which is the coupling agent and about 50% fibrous material.
32. The method according to claim 25, characterized in that it further comprises the step of mixing the nucleating agent and the first polypropylene material. and the coupling agent and the second polypropylene material homogeneously.
33. The method according to claim 25, characterized in that it further comprises the step of providing the nucleating agent and the first polypropylene material and the coupling agent and the second polypropylene material at a concentration of about 40% to 50%.
34. The method according to claim 33, characterized in that it further comprises the step of providing the fibrous material in a concentration of about 50% to 60%.
35. The method according to claim 25, characterized in that it further comprises the steps of: heating the structural mat to at least the melting temperature of the first and second polypropylene material; maintain the pressure to the structural mat; and forming a pressed board body from the mat.