Compressible mat of whole wood fibers and uncured resin as overlay for wood product and process of making same

Claim 1

A PROCESS OF MAKING AN OVERLAID WOODY PRODUCT, COMRISING; SCREEN FORMING A POROUS COMPRESSIBLE MAT CONSISTING ESSENTIALLY OF WHOLE WOOD FIBERS FROM AN AQUEOUS, FIBER SLURRY TO A THICKNESS OF FROM 0.1 TO 0.5 INCH THICK AND A SPECIFIC GRAVITY F FROM 0.15 TO 0.30; SAID FIBERS HAVING AN UNCURED SYNTHETIC RESIN SOLIDS PRECIPITATED UNIFORMLY THEREON IN AN AMOUNT OF AT LEAST ABOUT 5% BASED ON THE DRY FIBER WEIGHT; ADJUSTING THE MOISTURE CONTENT OF SAID POROUS MAT TO BETWEEN ABOUT 12% AND 200% BASED ON THE DRY FIBER WEIGHT; DISPOSING SAID MAT IN FACE TO FACE RELATION TO AN UNCONSOLIDATED SUBSTRATE OF ADHESIVE BEARING WOODY MEMBERS; CONSOLIDATING SAID SUBSTRATE AND MAT HEAT AND PRESSURE TO CURE THE RESIN AND ADHESIVE CONTENT AND PROVID SAID CURED MAT WITH A SPECIFIC GRAVITY OF BETWEEN ABOUT 0.7 AND 0.95, THEREBY FILLING ANY VOIDS IN THE SURFACE OF SAID SUBSTRATE.