A method for forming a product from cellulosic material and thermoactive
material is described. A mat is formed from a mixture having a
predetermined amount of cellulosic material and a predetermined amount of
thermoplastic material. The mat is then consolidated and pressed to a
predetermined final product thickness. At least a portion of a surface of
the mat or product is then surface modified. Consolidating the mixture may
include forming a first face layer, forming a core layer on the first face
layer, and forming a second face layer on the core layer. Forming the core
layer may include depositing mixtures of wood flakes and plastic flakes
according to mixture flake size in successive layers such that the core
layer has larger flakes adjacent the first face layer and adjacent the
second face layer, and smaller flakes in a middle portion of the core
layer. The method also can include fusing a sheet of plastic material to
at least one surface of the mat, and surface modifying the plastic
material. Grafting chemicals can be applied to surface modified mats,
plastic material or products. A composite product also is described. One
embodiment of the product comprises a first portion having a first core
formed from a mixture comprising a cellulosic material and a thermoplastic
material, and at least one face layer attached to the first core. The
product also comprises a second portion bonded to the first portion. The
second portion comprises a second core formed from a mixture comprising a
cellulosic material and a thermoplastic material, and at least one face
layer attached to the second core.
