| abstract |
A continuous process forms a unitary mat on a line having at least two conveyors spaced from each other. The process includes combining the isocyanate, an isocyanate catalyst, and a plurality of lignocellulosic particles to form a mixture and a self-polymerization product of the isocyanate in-situ in the mixture. The process also includes forming the unitary mat from the mixture on a first conveyer and transferring the unitary mat from the first conveyor to a second conveyor across a predetermined distance while maintaining structural integrity of the unitary mat. The lignocellulosic particles have a moisture content of 0.5 to 30 weight percent of water. Moreover, the continuous process is free of a step of adding water to the isocyanate, the isocyanate catalyst, the lignocellulosic particles, and/or the unitary mat. |