Gaf Corporation

Tarkett Inc.

Douglas C Woerner

Andrew James Manning

George R Ferment

Bengt A Tellvik

Kenneth J Faust

A relatively inexpensive mat is provided which through the application of heat and pressure readily can be densified to form rigid shaped articles. The mat is substantially free of a binder (e.g., a latex binder) and consists essentially of a substantially random array of (a) relatively coarse cellulosic fibers, (b) thermoplastic synthetic polymer fibrils, (c) non-fibrous thermoplastic synthetic polymer particles, and (d) substantially void-free substantially water-insoluble particulate inorganic material (e.g., talc) in the specified quantities. The mat preferably is formed by wet-laying from an aqueous dispersion wherein the (c) and (d) components are dispersed among and physically retained by the (a) and (b) components. A plurality of the mats while stacked may be subjected to heat and pressure to accomplish densification and thermal bonding within and between adjoining sheets to form a laminate. The resulting cellulosic fiber reinforced product can be used to advantage as a shaped rigid panel for use as an inner automobile door liner or in similar end uses which require a rigid sheet or panel having a predetermined configuration. A decorative surface optionally may be applied to the resulting article.

Relatively inexpensive thermoformable mat and rigid laminate formed

A relatively inexpensive mat is provided which through the application of heat and pressure readily can be densified to form rigid shaped articles having a reduced overall density. The mat is substantially free of a binder (e.g., a latex binder) and consists essentially of a substantially radom array of (a) relatively coarse cellulosic fibers, (b) thermoplastic synthetic polymer fibrils, (c) non-fibrous thermoplastic synthetic polymer particles, (d) substantially void-free substantially water-insoluble particulate inorganic material (e.g., talc), and (e) particulate void-containing substantially water-insoluble inorganic material (e.g., expanded volcanic glass) having a lesser density than component (d) in the specified quantities. A plurality of the mats while stacked together with similar mats of greater density on at least the upper and lower surfaces may be subjected to heat and pressure to accomplish densification and thermal bonding within and between adjoining mats to form a laminate. The presence of component (e) in conjunction with the other components has been found to enable the efficient control of the density in the resulting product regardless of the pressure applied during thermoforming. The resulting cellulosic fiber reinforced product can be used to advantage as a shaped rigid lightweight panel for use as an inner automobile door liner or in similar end uses which require a rigid sheet or panel having a predetermined configuration. A decorative surface optionally may be applied to the resulting article.

Relatively inexpensive thermoformable mat of reduced density and rigid

Flexible, sheet-type covering material is made by coating a porous mat with mechanically frothed plastic foam. The foam is gelled, at least partially fused and then calendered to crush the foam.

Flexible sheet-type covering material and process for making same

Flexible, sheet-type covering material having a porous mat substrate with a layer of mechanically frothed and crushed, heat cured, foamed thermoplastic vinyl polymer adhered to the substrate.

Flexible sheet-type covering material

Heat curable liquid polyvinylchloride plastisol or organosol resin is coated onto a porous fiber web in an amount sufficient to saturate the web. Liquid resin on one surface of the web is gelled by passing the web around a heated roll which, together with another heated roll, forms a compression nip. The web passes through the nip and around the second heated roll to gell the resin on the other surface of the web, after which the curing of the resin is completed in an oven.

Process for saturating a fiber mat of open structure

Decorative sheet-type covering material and method for making same. The material has a substrate comprising a porous mat saturated and completely coated on both sides with foamed, cured PVC plastisol or organosol. The substrate is made by coating one side of a porous mat with foamable PVC plastisol or organosol and then heating and foaming the plastisol or organosol.

Growing community of inventors

Northampton, PA, United States of America

Douglas C Woerner