A method to produce thin-layer lignocellulosic composites, such as
wood-based doorskins, that exhibit substantial resistance to moisture is
disclosed. In an embodiment, the method includes the steps of forming a
mixture including a refined lignocellulosic fiber, wax, and an organic
isocyanate resin. The mixture is initially pressed to form a loose mat.
Subsequently, the mat is pressed between two dies at an elevated
temperature and pressure to further reduce the thickness of the mat and
to promote the interaction of the resin with the lignocellulosic fibers.
In an embodiment, a release agent is included as part of the fiber
mixture, or sprayed onto the surface of the mat. The thin-layer
lignocellulosic composites of the present invention exhibit strong
surface strength, high adhesiveness, and a 50% reduction in linear
expansion and thickness swelling upon exposure to a high moisture
environment as compared to thin-layer composites that do not include the
isocyanate resin.